Hangar 9 P-40 Warhawk Assembly Manual Download Page 1

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Wingspan ................. 64.6 in (1641.5mm)

Wing Area ................ 709.4 sq in (45.8 sq dm)

Length ...................... 52 in (1321mm)

ASSEMBLY MANUAL

P-40 Warhawk

Weight ...................... 7.5–8.5 lb (3.4 kg–3.85 kg)

Recommended Engines .61–.75 2-stroke, .91–1.0 4-stroke

Radio ....................... 5-channel w/6 servos

Specifications

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Summary of Contents for P-40 Warhawk

Page 1: ... 1641 5mm Wing Area 709 4 sq in 45 8 sq dm Length 52 in 1321mm ASSEMBLY MANUAL P 40 Warhawk Weight 7 5 8 5 lb 3 4 kg 3 85 kg Recommended Engines 61 75 2 stroke 91 1 0 4 stroke Radio 5 channel w 6 servos Specifications ...

Page 2: ...Installing the Ailerons 14 Section 6 Installing the Elevators 16 Section 7 Rudder Installation 17 Section 8 Retract Linkage Installation 19 Section 9 Four Stroke Engine Installation 25 Section 10 Two Stroke Engine Installation 27 Section 11 Fuel Tank Assembly 30 Section 12 Radio Installation 34 Section 13 Linkage Installation 40 Section 14 Cowling Installation 44 Section 15 Canopy and Decal Instal...

Page 3: ...nsion JRPA099 2 Large Servo Arms w Screw JRPA212 Radio Switch JRPA003 900mAh receiver battery minimum Recommended Engines 61 2 stroke 1 00 4 stroke Recommended JR Systems XF421EX XP6102 XP662 X 378 XP9303 10X Small Parts 1 31 4 Wheels HAN2385 2 Fuel Tank HAN1987 3 Engine Mount HAN2033 4 Tailwheel Assembly HAN2855 Items Not Shown Decal Set HAN2856 Pushrod Set HAN2857 Cockpit and Exhaust Set HAN2858...

Page 4: ...e MMM20901 Canopy glue Formula 560 Other Required Items Epoxy Brushes DUB345 Fuel tubing Mixing Sticks for Epoxy DUB346 Paper towels Rotary tool w sanding drum Rubbing alcohol Ruler String Wax paper An RC aircraft is not a toy If misused it can cause serious bodily harm and damage to property Fly only in open areas preferably at AMA Academy of Model Aeronautics approved flying sites following all ...

Page 5: ...ation In no case shall Horizon Hobby s liability exceed the original cost of the purchased kit Further Horizon Hobby reserves the right to change or modify this warranty without notice In that Horizon Hobby has no control over the final assembly or material used for the final assembly no liability shall be assumed nor accepted for any damage of the final user assembled product By the act of using ...

Page 6: ...ing Step 3 Test the fit of the wing joiner into the remaining wing panel The joiner should again slide into the panel with little resistance up to the line drawn on the joiner Lightly sand the joiner as necessary to achieve a proper fit Step 4 Remove the covering in the leading edge for the wing dowels Locate a 1 4 x 13 16 wing dowel Use 30 minute epoxy to glue the wing dowels into the center pane...

Page 7: ...ottom of the joiner also Insert the epoxy coated side of the joiner into the wing joiner cavity up to the mark on the joiner If you have used enough epoxy it will ooze out of the cavity as the joiner is installed Remove any excess epoxy using a paper towel and rubbing alcohol Step 8 Apply epoxy to the exposed portion of the wing joiner Step 9 Apply epoxy to root wing rib of both panels Step 10 Car...

Page 8: ...for the two wing bolts Center the wing bolt plate on the wing and trace the placement of the plate onto the wing using a felt tipped pen Step 14 Remove the covering 1 16 inside the line drawn using a sharp hobby knife Remove the lines from the wing using rubbing alcohol and a paper towel Use medium CA to glue the plate in position Step 15 Use a 1 4 drill bit and drill through the wing bolt place f...

Page 9: ...iers or a C clamp to install the blind nut from the inside of the fuselage Note Make sure no epoxy gets into the threads of the blind nut Step 2 Use the two 1 4 x 11 2 socket head bolts and 1 4 washers to attach the wing to the fuselage Step 3 Measure the distance between a point centered at the rear of the fuselage and each wing tip The measurement will be equal if the wing is aligned correctly I...

Page 10: ...using a felt tipped pen Step 5 Remove a strip of covering that is 1 8 wide inside the lines drawn in the previous step Use care not to cut into the underlying wood weakening the wing structure Step 6 Use medium CA to glue the belly pan to the wing Section 2 Attaching the Wing ...

Page 11: ...as far forward as possible Center the stab in the opening by measuring the distance from the fuselage to each tip The stab is aligned when both measurements are identical Step 2 Check the distance from each stab tip to each wing tip These measurements must be equal for the stab to be aligned Step 3 Check to make sure the wing and stabilizer are parallel If they are not lightly sand the opening in ...

Page 12: ...ucture Doing so could cause the stab to fail in flight resulting in the loss of your airplane Step 6 Slide the elevator joiner wire into the slot for the stabilizer Slide the stabilizer partially back into the slot Step 7 Mix 1 2 ounce of 30 minute epoxy Apply epoxy to the top and bottom of the exposed wood of the stabilizer Slide the stabilizer the rest of the way into the slot in the fuselage Do...

Page 13: ...e underlying wood and weaken the structure Doing so could cause the fin to fail in flight resulting in the loss of your airplane Step 3 Slide the fin back into the fuselage Check the alignment of the fin to the stabilizer using a square The fin must be 90 degrees to the stabilizer when properly aligned If not carefully sand the bottom of the fin to provide the clearance to align the fin Step 4 Mix...

Page 14: ...1 64 inch Check to make sure the gap at both ends of the aileron are equal and that the aileron can move without rubbing on the wing Note Do not use CA accelerator during the hinging process The CA must be allowed to soak into the hinge to provide the best bond Using accelerator will not provide enough time for this process Step 4 Remove the T Pins and move the aileron to provide the best access t...

Page 15: ...cure and cannot be pulled apart Use caution when gripping the wing and aileron to avoid crushing the structure Step 6 Work the aileron up and down several times to work in the hinges and check for proper movement Step 7 Repeat Steps 1 through 6 for the remaining aileron Section 5 Installing the Ailerons ...

Page 16: ...s into the elevator half Step 3 Test fit the elevator and stab together The elevator joiner wire will be inserted into the hole drilled in the elevator Step 4 Lightly sand the joiner wire where it enters the elevator Mix 1 2 ounce of 30 minute epoxy and apply it to the groove and hole in the elevator half Insert the elevator joiner wire Remove any excess epoxy using rubbing alcohol and a paper tow...

Page 17: ...levator and stab to make sure the hinges are well glued Flex the elevators a few times to break in the hinges Step 7 Repeat Steps 1 through 6 to install the remaining elevator half Required Parts Fuselage assembly Rudder Tail wheel assembly Tail wheel bracket 2 x 3 8 sheet metal screw 2 Required Tools and Adhesives 6 minute epoxy Thin CA Drill Drill bit 1 8 T pins Step 1 Use a 1 8 drill to drill a...

Page 18: ...r wire Measure up 1 from the slight bend in the tail gear wire Bend the tail gear wire at a 90 degree angle back over the tail wheel Step 4 Roughen the tail gear wire using medium grit sandpaper where it will enter the rudder Use 6 minute epoxy to glue the wire into the rudder Step 5 Locate three CA hinges Place a T pin in the center of the hinges Place the hinges into the rudder Section 7 Rudder ...

Page 19: ...r the aileron servos through the holes and tape them to the top of the wing Required Parts Retract servo tray 31 4 main wheel 2 5 32 wheel collar 4 3mm set screw 4 Quick connector washer 2 Quick connector 2 Quick connector retainer 2 2mm wood screw 8 Retract servo tray mount 2 87 8 unthreaded retract wire 2 Required Tools and Adhesives 6 minute epoxy Masking tape Hex wrench included in kit Thick C...

Page 20: ...en installing the linkage make sure the actuator rod is moving to the full up and down positions without binding the servo Increase the throw by moving the linkage outward on the servo arm Decrease the throw by moving the linkage inward on the servo arm If the servo is binding it will add extra current draw to the receiver battery and will greatly reduce flight times Change the location of the lin...

Page 21: ... stall the servo placing unnecessary current loads on the receiver battery Adjust the retract up stop by screwing the set screw in slightly Again it only takes a small amount so start by turning it around 1 16 of a turn Do not tighten the set screw too much as the retract can bind and stall the servo placing unnecessary current loads on the receiver battery The adjustment procedure is common after...

Page 22: ...osition Step 4 Install a low profile retract servo in the servo tray using the hardware provided with the servo Prevent splitting the servo tray by drilling 1 16 holes for the servo mounting screws Step 5 Select a servo arm from those included with your servo that has a distance of about 1 between equally spaced holes as shown to start with Step 6 Use a 5 64 drill bit to drill the appropriate hole...

Page 23: ...s as necessary for proper operation of the retracts Once complete double check all set screws to make sure they are tight A little threadlock may also be a good suggestion for these set screws as well Hint Adjustments and fine tuning can also be made to the retract linkages from inside the wheel wells Remember It may take some time to get the retracts adjusted so the servo does not stall when the ...

Page 24: ...of the gear fairing Use a drop or two of thin CA in each hole to harden the underlying balsa Step 13 Secure the gear fairing to the wing using eight 2mm screws Step 14 Install a wheel and two wheel collars on the main landing gear The order of items is 5 32 wheel collar wheel and then another wheel collar Secure the collars using the 3mm set screws Step 15 Repeat Steps 11 through 14 to complete th...

Page 25: ...selage Hint You can also install the blind nuts backwards to prevent them from pulling into the wood on the backside of the firewall Just remember to move them to their correct positioning before moving to the next section Step 3 Position the engine on the mount and temporarily attach the engine using four 8 32 x 11 4 socket head screws four 8 washers and four nylon lock nuts Step 4 Position the e...

Page 26: ...th the wing dowel holes that corresponds to the side of the hole drilled in the firewall Make sure to drill so the pushrod won t interfere with the wing Step 8 Test fit the throttle pushrod tube through the firewall through former 2 and into the fuselage Once satisfied with the fit roughen the tube using medium sandpaper Slide the tube back into position and use medium CA to glue it to the firewal...

Page 27: ...and secure the engine to the firewall Required Parts Fuselage Engine mount 2 8 32 nylon lock nut 4 8 32 blind nut 4 8 washer 8 2 56 x 18 pushrod Plastic pushrod sleeve 12 8 32 x 1 socket head screw 4 8 32 x 11 4 socket head screw 4 Required Tools and Adhesives Hex Wrench 9 64 Ruler Socket wrench 11 32 Engine Drill Drill bit 5 32 Felt tipped pen Medium CA Step 1 Locate the engine mount and the asso...

Page 28: ...g before moving to the next section Step 3 Position the engine on the mount and temporarily attach the engine using four 8 32 x 11 4 socket head screws four 8 washers and four nylon lock nuts Step 4 Position the engine so the front of the drive washer is 51 8 from the firewall Tighten the bolts holding the engine once the engine is positioned Step 5 Center the engine mount in relation to the oval ...

Page 29: ...th the wing dowel holes that corresponds to the side of the hole drilled in the firewall Make sure to drill so the pushrod won t interfere with the wing Step 8 Test fit the throttle pushrod tube through the firewall through former 2 and into the fuselage Once satisfied with the fit roughen the tube using medium sandpaper Slide the tube back into position and use medium CA to glue it to the firewal...

Page 30: ...ps 2 Fuel pickup tubing Fuel tank Rubber stopper M3 x 20 screw Metal tubes short and long Fuselage assembly Required Tools and Adhesives Hobby knife Fuel tubing Foam 1 4 Masking tape Phillips screwdriver small Note The stopper provided with the P 40 has three holes that are not bored completely through the stopper The holes are for the fuel pickup fill and vent lines For these instructions only tw...

Page 31: ...of the rubber stopper This end will be inserted into the fuel tank The larger cap is placed on the side of the rubber stopper that makes the cap Loosely install the M3 x 20 screw through the center of the stopper Step 4 Bend the longer fuel tube carefully to a 45 degree angle using your fingers This will be the fuel tank vent tube Use care not to kink the tube while bending Step 5 Slide the vent t...

Page 32: ...n the tank to any attitude and the clunk will fall to the lowest point all directions except for having the stopper facing down Note The fuel tank is taller than it is wide Step 8 Tighten the M3 x 20 screw carefully do not over tighten This allows the rubber stopper to form a seal by being slightly compressed thus sealing the fuel tank opening Step 9 Mark the vent tube on the fuel tank This will b...

Page 33: ...ke sure the vent tube faces towards the top of the fuselage Note Make sure that any support braces installed will not interfere with the installation of the wing or linkages Step 12 Make the proper connections to the engine using the engine manufacturer s instructions If you are using a four stoke make sure to route the crankcase vent to the outside of the cowling Section 11 Fuel Tank Assembly ...

Page 34: ...e recommended servo hardware grommets and eyelets supplied with your radio system onto five servos elevator rudder throttle and 2 ailerons Step 2 Temporarily install the throttle servo Mark the locations for the servo screws using a felt tipped pen Step 3 Remove the servo and drill the holes for the servo mounting screws using a 1 16 drill bit Hint Place a drop of thin CA onto each screw hole to h...

Page 35: ...ds from becoming disconnected Note It is always a good idea to secure the servo connector and servo extension together to prevent the wires from becoming unplugged Step 7 Temporarily install the rudder servo Mark the locations for the servo screws using a felt tipped pen Remove the servo and drill the holes for the servo mounting screws using a 1 16 drill bit Secure the rudder servo using the scre...

Page 36: ...cessary extensions and Y harnesses necessary to connect the retract and aileron servos Connect the elevator rudder and throttle servo leads to the receiver Step 12 Use rubber bands to attach the receiver and battery to the radio tray It may be necessary to relocate the battery forward or aft to balance the model as described in the section Control Throws and Center of Gravity Section 12 Radio Inst...

Page 37: ... Remove the covering from the slot for the aileron horn Note The aileron servo is mounted directly to the hatch Step 16 Install the recommended servo hardware grommets and eyelets supplied with the servo Temporarily install a long half servo arm JRPA212 onto the servo and position the servo onto the hatch so the servo arm is centered in the notch Once satisfied mark the location for the servo moun...

Page 38: ...servo mounting blocks to clear the servo wire Step 19 Remove the servo and use a 1 16 drill bit to predrill the holes for the servo mounting screws marked in the previous step Use the screws supplied with the servo to mount it to the servo mounting blocks Step 20 Connect a 12 Servo Lead Extension JRPA098 to the servo lead Secure the connectors by tying them in a knot using dental floss as shown or...

Page 39: ...ur sides of the hatch Drill four 1 16 holes at the intersections of the lines as shown Note Drill through the servo hatch and the underlying hatch mounts Use caution not to accidentally drill through the top of the wing Step 23 Remove the servo hatch cover and re drill the holes using a 5 64 drill bit Use 2 3 drops of thin CA to harden the underlying wood This will prevent the screws from crushing...

Page 40: ...Drill Drill bit 1 16 5 64 3 32 Phillips screwdriver small Step 1 Thread a clevis onto a 7 wire a minimum of 10 turns Step 2 Remove the back plate from a control horn using side cutters or a sharp hobby knife Step 3 Position the control horn on the elevator so the horn aligns with the hinge line of the elevator Mark the position for the mounting holes using a felt tipped pen Step 4 Drill three 3 32...

Page 41: ...r the elevator servo electronically using the radio system Install a servo arm onto the elevator servo Attach the pushrod with clevis to the control horn Physically place the elevator control surface in neutral Mark the pushrod where it crosses the holes in the servo arm Step 8 Bend the wire 90 degrees at the mark made in the previous step Step 9 Cut the wire 3 8 above the bend Section 13 Linkage ...

Page 42: ...back plate from the control horn using side cutters or a sharp hobby knife Step 13 Position the control horn on the aileron so the horn aligns with the aileron servo horn and the aileron hinge line Mark the position for the mounting holes using a felt tipped pen Step 14 Drill three 3 32 holes at the locations marked in the previous step Step 15 Attach the control horn using three 2 56 x 1 screws a...

Page 43: ...8 above the bend Step 19 Slide the wire through the outer hole in the aileron servo arm Secure the wire using a nylon wire keeper Step 20 Repeat Steps 16 through 19 for the other aileron servo Step 21 Use a 5 64 drill bit to drill a hole in the throttle servo arm Step 22 Attach a quick connector to the servo arm using quick connector washers and retainers Step 23 Center the throttle stick and trim...

Page 44: ...ny binding Install the throttle servo arm screw when complete Step 26 Use scrap wood to make a brace for the throttle pushrod tube near the servo Required Parts Fuselage assembly Cowling 4 x 5 8 sheet metal screw 4 Required Tools and Adhesives Drill Drill bit 1 8 3 32 Hobby scissors 6 minute epoxy Ruler Hobby knife Phillips screwdriver small Rotary tool with sanding drum Step 1 Use a rotary tool h...

Page 45: ... cowl over the engine Note Start by removing only a little material at a time You can always make the holes bigger as you work Work until the cowl fits nicely over the engine Step 4 Slide the cowling onto the fuselage Temporarily install the propeller and spinner back plate Position the cowl so there is 1 8 gap between the back plate and the cowl Step 5 Locate the screws to secure the cowl 3 4 for...

Page 46: ...g using 6 minute epoxy Step 2 Use hobby scissors to trim the backrest Use Zap A Dap A Goo to glue the backrest into position Required Parts Fuselage assembly Canopy Decal 2 x 1 2 sheet metal screw 2 Required Tools and Adhesives Canopy glue Formula 560 Sandpaper medium grit Hobby scissors Zap A Dap A Goo 6 minute epoxy Step 1 Paint and install a pilot of your choosing Use epoxy or Zap A Dap A Goo t...

Page 47: ...de edge of the canopy and slightly inside the line drawn on the hatch using medium sandpaper Step 4 Apply a bead of RCZ56 Canopy Glue ZINJ5007 around the inside edge of the canopy Position the canopy onto the hatch Use tape to hold the canopy secure until the glue fully cures Step 5 Apply the decals Use the photos on the box to aid in their location Section 15 Canopy and Decal Installation ...

Page 48: ...ectronically at the radio By moving the position of the clevis at the control horn toward the outermost hole you will decrease the amount of control throw of the control surface Moving it toward the control surface will increase the amount of throw Moving the pushrod wire at the servo arm will have the opposite effect Moving it closer to center will decrease throw and away from center will increas...

Page 49: ...most cases the radio should be charged the night before going out flying Check the radio installation and make sure all the control surfaces are moving correctly i e the correct direction and with the recommended throws Test run the engine and make sure it transitions smoothly from idle to full throttle and back Also ensure the engine is tuned according to the manufacturers instructions and it wil...

Page 50: ...explosive gases such as hydrogen filled balloons or ground mounted devices launching a projectile The only exceptions permitted are rockets flown in accordance with the National Model Rocketry Safety Code or those permanently attached as per JATO use also those items authorized for Air Show Team use as defined by AST Advisory Committee document available from AMA HQ In any case models using rocket...

Page 51: ...used no powered model may be flown closer than 25 feet to any person 9 Under no circumstances may a pilot or other person touch a powered model in flight Organized RC Racing Event 10 An RC racing event whether or not an AMA Rule Book event is one in which model aircraft compete in flight over a prescribed course with the objective of finishing the course faster to determine the winner A In every o...

Page 52: ... 2005 Horizon Hobby Inc 4105 Fieldstone Road Champaign Illinois 61822 877 504 0233 www horizonhobby com 7334 ...

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