Hangar 9 Piper J-3 Cub 40 Assembly Manual Download Page 3

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Using the Manual

This.manual.is.divided.into.sections.to.help.make.assembly.easier.to.understand,.and.to.provide.breaks.between.each.

major.section..In.addition,.check.boxes.have.been.placed.next.to.each.step.to.keep.track.of.each.step.completed..Steps.

with.a.single.box.(



).are.performed.once,.while.steps.with.two.boxes.(



).indicate.that.the.step.will.require.

repeating,.such.as.for.a.right.or.left.wing.panel,.two.servos,.etc..Remember.to.take.your.time.and.follow.the.directions.

Required Tools and Adhesives

Tools

•.Rotary.tool.(Dremel).

•.Hobby.scissors

•.Pliers. .

•.Clamp

•.T-pins. .

•.Crimping.tool/vice.grips

•.Solder. .

•.String

•.Solder.gun.

•.1/4-inch.(6mm).foam

•.Tape.

•.Hobby.knife

•.Phillips.screwdriver.

•.Drill

•.Felt-tipped.pen.

•.Nut.driver:.1/4-inch

•.Hex.wrench:.5/64-inch,.3/32-inch,.7/64-inch,.1/8-inch
•..Drill.bit:.1/16-inch.(1.5mm),.5/64-inch.(2mm),.5/32-inch.(4mm),.3/16-inch.(4.5mm)

Adhesives

•.Thin.CA.(PAAPT08).

•.Medium.CA.(PAAPT02)

•.30-Minute.Epoxy.(HAN8002).

•.Formula.560.Canopy.Glue.(PAAPT56)

•.CA.Remover/Debonder.(PAAPT16).

•.Pacer.Z-42.Threadlock.(PAAPT42)

UltraCote Covering Colors

•.Cub.Yellow.

HANU884

Before Starting Assembly

Before.beginning.the.assembly.of.the.Piper.J-3.Cub,.remove.each.part.from.its.bag.for.inspection..Closely.inspect..

the.fuselage,.wing.panels,.rudder,.and.stabilizer.for.damage..If.you.find.any.damaged.or.missing.parts,.contact.the..

place.of.purchase.
If.you.find.any.wrinkles.in.the.covering,.use.a.heat.gun.or.sealing.iron.to.remove.them..Use.caution.while.working.around.

areas.where.the.colors.overlap.to.prevent.separating.the.colors.

HAN100 – Heat Gun

HAN150 – Covering Glove

HAN101 – Sealing Iron

HAN141 – Sealing Iron

Sock

Summary of Contents for Piper J-3 Cub 40

Page 1: ...m Wing Area 1630 sq in 10 52 sq dm Length 68 in 1727mm Weight 14 5 16 5 lb 6 6 kg 7 5 kg Assembly manual Piper J 3 Cub Engine 1 00 1 80 Four Stroke 1 00 1 60 Two Stroke 20 26cc Gasoline Motor E flite Power 110 Specifications ...

Page 2: ... 6 Warranty Inspection and Repairs 6 Non Warranty Repairs 6 Safety Precautions and Warnings 7 Contents of Kit 7 Hinging the Control Surfaces 8 Landing Gear Installation 10 Stabilizer Installation 13 Aileron Servo Installation 16 Radio Installation 20 Engine Installation Glow 26 Engine Installation Gas 30 Interior Detail Installation 33 Wing Installation 36 Control Throws 39 Recommended Center of G...

Page 3: ... pen Nut driver 1 4 inch Hex wrench 5 64 inch 3 32 inch 7 64 inch 1 8 inch Drill bit 1 16 inch 1 5mm 5 64 inch 2mm 5 32 inch 4mm 3 16 inch 4 5mm Adhesives Thin CA PAAPT08 Medium CA PAAPT02 30 Minute Epoxy HAN8002 Formula 560 Canopy Glue PAAPT56 CA Remover Debonder PAAPT16 Pacer Z 42 Threadlock PAAPT42 UltraCote Covering Colors Cub Yellow HANU884 Before Starting Assembly Before beginning the assemb...

Page 4: ...ektrum Systems XP9303 XP7202 DX7 XP6102 XS600 Recommended Setup Gas Glow Zenoah 20cc Electronic Ignition ZENE20EI OR 38mm stand offs Zenoah only EVO3307 RF choke ring gas only JRPA029 Saito 180 AAC with Muffler SAIE180 or SAIE180GK Muffler Right Angle Adapter Saito only SAI120S140 16x6 Propeller Propeller nut Recommended Setup Electric E flite Power 110 BL Outrunner Motor EFLM4110A Castle Creation...

Page 5: ... any part of the Product This warranty does not cover damage due to improper installation operation maintenance or attempted repair by anyone other than Horizon Return of any goods by Purchaser must be approved in writing by Horizon before shipment Damage Limits HORIZON SHALL NOT BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CON...

Page 6: ...ranty Inspection and Repairs To receive warranty service you must include your original sales receipt verifying the proof of purchase date Provided warranty conditions have been met your Product will be repaired or replaced free of charge Repair or replacement decisions are at the sole discretion of Horizon Hobby Non Warranty Repairs Should your repair not be covered by warranty the repair will be...

Page 7: ... out of the reach of children Moisture causes damage to electronics Avoid water exposure to all equipment not specifically designed and protected for this purpose Contents of Kit Replacement Parts A HAN4551 25 J 3 Cub Fuselage B HAN4552 25 J 3 Cub Left Wing w Aileron C HAN4553 25 J 3 Cub Right Wing w Aileron D HAN4554 25 J 3 Cub Stab and Elevator Set E HAN4555 25 J 3 Cub Rudder F HAN4556 25 J 3 Cu...

Page 8: ...he stabilizers Note While your rotary tool is out drill the holes in the elevators ailerons wing rudder and fin as well Step 2 Place a T pin in the center of three CA hinges Step 3 Position the hinge in the stabilizer The slot in the hinge will align with the hole drilled in the stabilizer Step 4 Slide the hinges in the elevator Position the stabilizer and elevator so there is as little gap betwee...

Page 9: ...e CA accelerator on the hinges The CA must be allowed to wick fully into the hinge to provide the best bond between the hinge and the surrounding wood Step 6 Allow the CA plenty of time to cure Once cured pull on the elevator and stabilizer to make sure the hinges are fully glued into position Step 7 Flex the elevator up and down a number of times to break in the hinges Hinging the Control Surface...

Page 10: ...ench 3 32 inch 1 8 inch Nut driver 1 4 inch Note Be sure the 6 32 bolts that secure the landing gear legs to the landing brackets are snug to minimize vibration but allow for movement Step 1 Locate the left and right main gear struts and the wing strut tab Attach the front of the landing gear using two 8 32 x 3 4 inch socket head screws The rear is also secured to the fuselage using four 8 32 x 3 ...

Page 11: ...ace Step 3 Locate the main wheel and remove the front and rear hubs from the wheel Step 4 Secure the wheel collar to the axle by tightening the setscrew onto the flat of the axle with the included hex wrench Note Use threadlock on the setscrew to prevent it from vibrating loose in flight Step 5 Slide the rear hub into the wheel The rear hub is identified as the one without the holes going through ...

Page 12: ...lling the screws If the wheel does not rotate loosen the screws slightly until it does Step 7 Use a 4 40 setscrew to secure the axle to the main landing gear Note Use threadlock on the setscrew to prevent them from vibrating loose in flight Step 8 To complete the wheel installation snap the hub cap onto the wheel Step 9 Repeat Steps 3 through 8 to install the remaining wheel Landing Gear Installat...

Page 13: ...oiner into the forward hole in the stabilizer Step 2 Slide the stabilizer into the slot in the fuselage Use two 6 32 x 3 4 inch socket head screws and two 6 washers to secure the stabilizer Note Leave the screws loose until instructed to tighten them Step 3 Slide the remaining stabilizer into the slot in the fuselage The tubes from the first stabilizer will key into the second stabilizer Use two 6...

Page 14: ...inch socket head screw and a 4 40 locknut There will be a bracket on the right and left of the fin when complete Step 6 Remove the clevis from each of the support rods Use a hobby knife to clean the paint from the threads Thread a 2 56 nut onto the threads then replace the clevis Step 7 Use a 4 40 x 5 8 inch socket head screw and 4 40 locknut to attach the support rods to the stabilizer The longer...

Page 15: ...n of the clevis to ensure the support rods are not causing any twists between the fuselage stabilizer and fin Tighten the nuts against the clevises once all adjustments have been made Note Use threadlock on the nuts and clevises to prevent them from vibrating loose in flight Stabilizer Installation ...

Page 16: ...There is a right and left cover so make sure when the hatch is positioned the slot for the servo arm lines up Step 2 Install a long servo arm onto the aileron servo Remove the excess arms that will not extend out from the wing Position the servo so the arm is centered in the opening for the arm Use a felt tipped pen to mark the location of the servo on the cover Note The mounting tabs for the serv...

Page 17: ...g screws onto the blocks Step 6 Drill the marked locations using a drill and 1 16 inch 1 5mm drill bit Use the hardware provided with the servo to secure it to the blocks Step 7 Use string or a commercially available connector to secure a 18 inch 457mm servo extension to the servo lead Step 8 Tie a weight to a 24 inch 610mm piece of string Lower the weight into the wing and pull it out at the open...

Page 18: ...atch cover and secure it using four 2 x 1 2 inch sheet metal screws After installing the screws remove them and apply a few drops of thin CA to the holes to harden the wood to prevent the screws from vibrating loose Step 11 Assemble the aileron pushrod by sliding the safety fuel tubing onto two metal clevises Thread the two metal clevises and two 4 40 nuts onto a 43 4 inch 120mm pushrod Aileron Se...

Page 19: ...a 5 64 inch 2mm drill bit to drill the three holes for the control horn screws Apply a few drops of thin CA into each hole to harden the wood to aid in preventing the wood from being crushed when the horn is installed Step 14 Secure the control horn to the aileron using three 2 56 x 1 inch machine screws and the control horn backplate Note Once the length of the linkage has been adjusted use threa...

Page 20: ...obby knife Felt tipped pen Thin CA Crimping tool vice grips Pliers 1 4 inch 6mm foam Drill bit 1 16 inch 1 5mm 5 64 inch 2mm Step 1 Locate the 331 4 inch 845mm elevator pushrod and a 4 40 ball end Thread the ball end onto one end of the rod a minimum of 14 turns Step 2 Attach the ball end to a large servo horn Use side cutters to remove the remaining arm from the horn Step 3 Slide the pushrod into...

Page 21: ...the positions for the three control horn mounting screws Align holes with hinge line Step 6 Use a 5 64 inch 2mm drill to drill through the elevator for the control horn mounting screws Step 7 Apply a few drops of thin CA into each of the holes to harden the surrounding wood Step 8 Attach the control horn to the elevator using three 2 56 x 5 8 inch machine screws and the control horn backplate Note...

Page 22: ...ogrammable mixing You will need to use two separate channels and use your radio to mix them together electronically for this option to work Option 2 Use two servos and a JR MatchBox or a 6 standard reversing Y harness EXRA320 to link the two elevator servos to operate properly Option 3 Use a standard rotation servo and a reverse rotation servo and a standard Y harness Note The cable will be instal...

Page 23: ...he ball ends Step 15 Install the rudder servo into the fuselage and attach the servo horn to the servo using the hardware provided with the servo The output of the servo faces the front of the fuselage Note that the cables cross once inside the fuselage The cable from the right side of the servo exits the left of the fuselage and vice versa Step 16 Place light tension on the cable and align it so ...

Page 24: ...onto a rigging coupler Slide a crimp onto the cable then slide the cable through the coupler The cable will then go back through the crimp Prepare both ends of the cable and attach the clevises to the control horns Adjust the cable so there is light tension on the cable then secure the cable using the crimp and crimping pliers or vice grips Make sure to install that safety fuel tubing on those cle...

Page 25: ...inch sheet metal screws Step 23 Install a choke ring JRPA029 on each of the the 18 inch 457mm aileron extensions that are plugged into the receiver These will be hidden under the radio tray This is strongly recommended due to all the metal struts on the Cub Step 24 Plug two 18 inch 457mm servo extensions into the receiver and route them through the holes in the sides of the fuselage and up to the ...

Page 26: ... Threadlock Clamp Medium CA Phillips screwdriver Hex wrench 3 32 inch 9 64 inch Drill bit 1 16 inch 1 5mm 5 32 inch 4mm 3 16 inch 4 5mm Step 1 Place the firewall template in position on the firewall Drill the locations for your particular engine using a 1 16 inch 1 5mm drill bit Drill the location for the throttle pushrod at this time as well Step 2 Remove the template and enlarge the holes using ...

Page 27: ...h 4mm drill bit Step 6 Slide the throttle pushrod tube into the hole drilled in the firewall The tube will extend forward of the firewall slightly Use medium CA to glue the tube to the firewall Note It may be necessary to rotate the carburetor to align with the throttle pushrod tube Check the alignment before attaching the engine to the engine mount Step 7 Use four 8 32 x 11 2 inch socket head scr...

Page 28: ... rod and attach the clevis to the servo arm Step 10 Check the operation of the throttle servo to make sure it doesn t bind and the throttle will move from open to closed Make any adjustment at this time to the throttle linkage as necessary Step 11 Slide the fuel tank into the fuselage with the stopper facing toward the top of the fuselage Use a rubber band to keep the fuel tank from moving rearwar...

Page 29: ...on t have to be removed to fuel the engine Note You will need to use a Muffler Right Angle Adapter SAI120S140 when installing the Saito engines Step 14 Attach the cowling using four 4 40 x 1 2 inch socket head screws four pieces of cowl screw tubing and four 4 washers Install the propeller to complete the engine installation Engine Installation Glow ...

Page 30: ...2 inch 9 64 inch Drill bit 1 16 inch 1 5mm 3 16 inch 4 5mm Step 1 Place the firewall template in position on the firewall Drill the locations for your particular engine using a 1 16 inch 1 5mm drill bit Drill the location for the throttle pushrod at this time as well Step 2 Remove the template and enlarge the holes using a 3 16 inch 4 5mm drill bit Step 3 Slide the throttle pushrod tube into the h...

Page 31: ...set them aside Prepare the tubing by placing a drop of solder on the ends of the brass tubing as shown This will keep the fuel line from slipping off the tube when combined with the following steps Step 7 Slide gas compatible fuel lines back onto the brass tubes Use fine wire to secure the fuel lines The wire is placed behind the solder applied in the previous step to keep the tubes in place Step ...

Page 32: ... should be placed next to the fuel tank behind the firewall This is to keep as much separtation between the ignition and the RX The battery pack should be installed before installing the fuel tank The model was flown with the battery pack placed here when using the Zenoh 20ei Step 11 Trim the cowling as necessary to clear the muffler carburetor and head of the engine Secure the cowling using four ...

Page 33: ...ium CA Phillips screwdriver Hobby knife Hobby scissors 30 minute epoxy Canopy glue Step 1 Install the switch harness into the opening in the rear seat bottom Step 2 Use medium CA to glue the rear seat back to the rear seat bottom Step 3 Plug the switch harness into the battery and receiver Slide the rear seat into position guiding the wires from the switch harness behind the seat Step 4 Glue the f...

Page 34: ...l keep the seats from sliding in the fuselage Step 6 Use medium CA to glue the instrument panel into the fuselage Step 7 Use 30 minute epoxy to glue the windscreen supports into position as shown Step 8 Use canopy glue to glue the front windscreen onto the fuselage as shown Interior Detail Installation ...

Page 35: ... 10 Trim the rear window and use canopy glue to secure the rear window in position Step 11 Repeat Steps 9 and 10 for the opposite side windows Step 12 Complete the window installation by trimming and installing the upper window in the fuselage Step 13 Use hook and loop to secure the pilot in the fuselage Interior Detail Installation ...

Page 36: ...ch Threadlock Nut driver 1 4 inch Step 1 Attach the wing strut wing brackets to the bottom of the wing using four 4 40 x 3 4 inch socket head screws Note Use threadlock on the screws to prevent them from vibrating loose in flight Step 2 Thread two of the mid span studs into the wing The threads of the studs should be flush to the top of the wing Step 3 Attach the front and rear wing strut to the b...

Page 37: ... 3 8 inch socket head screws and 4 40 locknuts The supports attach to the mid span studs using two long strut pins and two retainer clips Step 6 Slide the aluminum wing tube into the fuselage The wing is then slid onto the wing tube Plug the servo lead in the wing into the extension inside the fuselage Step 7 The wing is held in place using a 1 4 20 nylon wing bolt Wing Installation ...

Page 38: ...rut ends into the brace at the fuselage It will be necessary to adjust the strut ends to align without binding or twisting the wing Once adjusted tighten the 4mm nuts against the ends to prevent them from changing position Note Use threadlock on the strut ends and 4mm nuts to prevent them from vibrating loose in flight Step 9 Secure the strut ends to the wing using two retainer pin clips Wing Inst...

Page 39: ...down Note Elevator throw is measured at the trailing edge of the elevator next to the fuselage Rudder High Rate 21 4 inch 57mm left right Low Rate 11 2 inch 38mm left right Note Rudder throw is measured at the bottom of the rudder An important part of preparing the aircraft for flight is properly balancing the model This is especially important when various engines are mounted Caution Do not inadv...

Page 40: ...hat your engine idles reliably transitions and runs at all throttle settings Only when this is achieved should any plane be considered ready for flight Range Test Your Radio Before each flying session be sure to range check your radio See your radio manual for the recommended range and instructions for your radio system Each radio manufacturer specifies different procedures for their radio systems...

Page 41: ...41 Building and Flying Notes ...

Page 42: ...with metal blade propellers or with gaseous boosts other than air nor will I operate model aircraft with fuels containing tetranitromethane or hydrazine 8 I will not operate model aircraft carrying pyrotechnic devices which explode burn or propel a projectile of any kind Exceptions include Free Flight fuses or devices that burn producing smoke and are securely attached to the model aircraft during...

Page 43: ... site a day use agreement between sites or testing which determines that no interference exists A frequency management agreement may exist between two or more AMA chartered clubs AMA clubs and individual AMA members or individual AMA members Frequency management agreements including an interference test report if the agreement indicates no interference exists will be signed by all parties and copi...

Page 44: ... 2007 Horizon Hobby Inc 4105 Fieldstone Road Champaign Illinois 61822 877 504 0233 horizonhobby com 9942 ...

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Hangar 9 Piper J-3 Cub 40, Assembly Manual

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