Hangar 9 Twin Otter ARF Assembly Manual Download Page 2

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Table of Contents

Contents of Kit and Parts Layout.................................2

Included Hardware.......................................................3

Introduction..................................................................4

Important Warranty Information...................................4

Recommended Setup–2-stroke Glow..........................4

Recommended Setup–Electric Power (EP)................4

Radio Equipment Requirements..................................4

Transmitter Requirements...........................................4

Required Tools and Equipment....................................4

Required Adhesives.....................................................4

UltraCote Covering Colors...........................................4

Field Equipment Required...........................................4

Other Required Items..................................................4

Using the Manual.........................................................5

Before Starting Assembly.............................................5

Product Registration....................................................5

Work Area Cleanliness.................................................5

Optional Accessory......................................................5

Workspace Preparation...............................................5

Elevator Servo Installation...........................................6

Aileron Servo Installation.............................................9

Flap Servo Installation...............................................12

Nacelle Installation.....................................................16

Motor, ESC and Battery Installation............................17

Cowling, Propeller and Spinner Installation–EP........20

2-Stroke Installation...................................................21

Cowling, Propeller and Spinner Installation................27

Rudder Hinging.........................................................28

Rudder Servo and Linkage Installation.......................29

Nose Gear and Steering Servo Installation..................32

Main Landing Gear Installation..................................35

Nose Cone Installation..............................................37

Receiver, Battery and Switch Installation..................37

Final Assembly...........................................................38

Center of Gravity........................................................41

Control Throws..........................................................41

Flight Preparations.....................................................42

Maintaining Your Model..............................................42

Safety Do’s and Don’ts for Pilots................................43

Dual Rates.................................................................43

Age Requirements.....................................................43

Daily Flight Checks....................................................43

Flying Tips.................................................................44

Build and Flying Notes...............................................44

Warranty Information.................................................45

Compliance Information for the European Union......46

2010 AMA Safety Code.............................................47

Contents of Kit and Parts Layout

1 HAN461001

Fuselage Assembly with Hatch 12

HAN461012

Left Main Gear

2 HAN461002

Cowling

HAN461013

Right Main Gear

3 HAN461003

Left Nacelle

HAN461014

Wing and Tail Tubes

4 HAN461004

Right Nacelle

HAN461015

Landing Gear Fairings

5 HAN461006

Left Stabilizer

HAN461020

2 1/4-inch Black Spinners

6 HAN461005

Right Stabilizer

HAN461021

Fiberglass Nose Cone

7 HAN461007

Rudder

Not Illustrated

8 HAN461008

Left Wing

HAN461016

Electric Mounting Pack

9 HAN461009

Right Wing

HAN461017

Glow Mounting Pack

10 HAN461010

Struts

HAN461018

Main Hardware Pack

11 HAN461011

Nose Gear Assembly

HAN461019

Fuel Tanks

Twin Otter ARF Assembly Manual

Summary of Contents for Twin Otter ARF

Page 1: ...ter ARF Assembly Manual Specifications Wingspan 82 0 in 2080mm Length 65 0 in 1651mm Wing Area 738 sq in 47 61 sq dm Weight 11 1 2 12 1 4 lb 5 2 6 0 kg Radio 7 channel w 8 10 servos Engine 36 2 stroke Power 25 ...

Page 2: ...tallation 35 Nose Cone Installation 37 Receiver Battery and Switch Installation 37 Final Assembly 38 Center of Gravity 41 Control Throws 41 FlightPreparations 42 Maintaining Your Model 42 Safety Do s and Don ts for Pilots 43 Dual Rates 43 Age Requirements 43 Daily Flight Checks 43 Flying Tips 44 Build and Flying Notes 44 Warranty Information 45 Compliance Information for the European Union 46 2010...

Page 3: ...dder cable 82 inch 1 rudder cables Copper crimps 4 Wire cable ends 2 EZ links 2 rudder servo Main Hardware Bag 8 32 x 1 inch Allen head machine screws 6 main landing gear 4 x 7 16 inch wood screws 3 nose cone 4 40 x 1 inch Allen head machine screws 2 strut to wing attach 8 32 x 1 inch Allen head machine screws 4 nose gear attach Glow Engine Mount Bag Small nylon engine mount 4 engine 6 32 x 1 inch...

Page 4: ...rvo 6 SPMSA6000 JR SPORT MC35 Micro Servo 4 JSP20030 Note Two less micro servos required for EP version 9 inch Servo Extension 7 JRPA097 36 inch Servo Extension 2 JRPA103 Y Harness 3 JRPA135 Receiver Battery 6 volt 2300mAh JRPB5006 JR Chargeswitch JRPA004 Ailerons A6000 Servo 2 9 inch Extension connected to servos 2 Y harness connected to receiver Flaps A6000 Servo 2 9 inch Extension connected to ...

Page 5: ...ents such as the radio and engine or motor Tape over engine intake and exhaust ports when drilling or cutting the firewall and cowling to prevent causing damage to the internal components Optional Accessory Setting up servos is a whole lot easier with a JR MatchMaker It lets you accurately center servos evaluate endpoints and cycle servos at varying speeds without ever having to switch on a transm...

Page 6: ...os by installing rubber mounting grommets and brass bushings Note that the bushings are installed from the bottom of the servo Step 2 Use a 1 Phillips screwdriver to remove the small arm from the servo Use sidecutters to remove three arms from a standard 4 way servo arm leaving one long arm Center the servo using your radio and install the arm as shown Step 3 Repeat step 2 to install the arm on th...

Page 7: ... the blocks with a pencil Step 9 Remove the servo and use a 1 16 inch drill bit in a pin vise to drill the mounting holes Apply a small drop of thin CA to each of the holes to strengthen the wood Allow the CA to cure without using accelerator Step 10 Use a 1 Phillips screwdriver and the hardware provided with the servo to install it on the hatch Be sure to maintain a 1 32 inch gap between the serv...

Page 8: ...stabilizer root and set the hatch in place Step 14 Use a 1 Phillips screwdriver to secure the hatch to the stabilizer with four 2 x 3 8 inch woodscrews Step 15 Slide a silicone keeper onto a 4 inch steel elevator pushrod then thread on a clevis so it is centered on the threads Step 16 Center the elevator by aligning the balance tab to the stabilizer Secure it in place with low tack tape on both th...

Page 9: ...p 21 Repeat steps 4 through 19 to install the servo in the opposite stabilizer half Aileron Servo Installation Parts Required Wing panels left and right Servos with hardware 2 Clevises 2 Snap keepers 2 Silicone keepers 2 4 inch steel pushrods 2 9 inch servo extension leads 2 2 x 3 8 inch woodscrews 8 10 x 11 x 20mm servo mounting blocks 4 Radio Tools Required Ruler 1 Phillips screwdriver Pin vise ...

Page 10: ...rection Step 4 Use a 5 64 inch drill bit in a pin vise to enlarge the outer hole in each servo arm Step 5 Remove the hatch from the wing and position the servo against the inside surface so that it is equally spaced in the long direction of the hatch There will be approximately a 3 16 inch gap at each end Step 6 Align the servo arm with the top edge of the hatch and mark the mounting lug locations...

Page 11: ...stall the servo with its provided hardware Step 11 Attach a 9 inch servo extension lead to the servo and secure the connection with a piece of dental floss Hint Apply a very small drop of thin CA to the knot to prevent it coming loose Step 12 Use a 1 Phillips screwdriver to thread a 2 x 3 8 inch screw into each of the hatch mounting holes in the wing Remove the screw and apply a small drop of thin...

Page 12: ...o make a 90 degree bend at the mark Trim the bent portion of the pushrod to a length of 1 4 inch using sidecutters Step 19 Attach the clevis to the outer hole of the control horn and secure it with the silicone keeper Slide the bent portion of the pushrod through the outer hole of the servo arm and secure it with a snap keeper Step 14 Use a 1 Phillips screwdriver to install the aileron hatch with ...

Page 13: ...10 x 11 x 20mm servo mounting blocks 4 2 x 3 8 inch woodscrews 8 Tools Required Ruler 1 Phillips screwdriver Pin vise 5 64 inch drill bit Pliers Sidecutters Pencil Thin CA 30 minute epoxy Mixing sticks Mixing cups Note the left hand side installation is shown here Step 1 Prepare two flap servos by installing grommets and bushings Note that the bushings are installed from the bottom of the mounting...

Page 14: ...tep 6 Use a pencil to mark the servo mounting locations on the hatch Step 7 Mix a small amount of 30 minute epoxy and glue the 10 x 11 x 20mm mounting blocks to the hatch Orient the blocks so they do not protrude beyond the edge of the hatch Step 8 Place the servo on the mounting blocks with a 1 32 inch gap between it and the hatch Use a pencil to mark the mounting hole locations Step 9 Use a 5 64...

Page 15: ... is centered on the threads Measure 2 inches from the clevis pin and use pliers to make a 90 degree bend at that location Trim the bent portion of the pushrod to a length of 1 4 inch Step 13 Deflect the flap and insert the pushrod through the hole in the wing trailing edge with the bend towards the wing root left hand side Attach the clevis to the flap horn and secure it with the silicone keeper S...

Page 16: ...ow tack tape 30 minute epoxy Mixing sticks Mixing cups Paper towels Felt tipped pen Canopy glue 2 3 4 inch wooden dowel Step 1 Identify the left and right hand nacelles The larger hole on the lower surface of the nacelle locates to the inboard side to receive the wing strut Label each nacelle and wing panel with low tack tape to prevent installing them incorrectly Step 2 Remove the hatch and cowl ...

Page 17: ...and right Motors 2 ESC 2 19mm standoffs Firewall drilling template 4 steel washers 8 4 40 blind nuts 8 Batteries 2 Hook and loop strap 2 9 inch servo extensions 2 4 40 x 1 1 4 inch Allen head machine screws 8 Double sided adhesive tape not included Cable ties not included Tools Required Felt tipped pen 1 Phillips screwdriver Drill motor Low tack tape Pin vise Ruler 1 16 inch drill bit 9 64 inch dr...

Page 18: ... 5 8 inch from the right hand side of the firewall and mid way between the upper and lower mount holes Make a mark with a felt tipped pen Step 7 Use a tapered reamer to make a 1 2 inch hole through the firewall at the marked location Step 8 Cut a hook and loop strap to a length of 8 inches using scissors Slide it through the aft set of slots in the nacelle floor Step 9 Connect a 9 inch servo exten...

Page 19: ...nch hex wrench to install the motor and 19mm standoffs Mount the motor with the leads to the right hand side Step 12 Connect the motor leads to the ESC Step 13 Use cable ties to secure the leads so they cannot interfere with operation of the motor Step 14 Insert the battery and secure it with the hook and loop strap You may choose to use adhesive backed hook and loop tape not included under the ba...

Page 20: ...piece of low tack tape to the aft edge of the cowling on both sides Align it flush to the aft edge and just above the blue trim line Step 2 Use a felt tipped pen to mark a line on the tape 1 4 inch forward of the aft edge Step 3 Measure 5 8 and 2 1 4 inches above the top of the blue trim line and make two marks with a felt tipped pen Step 4 Use a 1 16 inch drill bit in a pin vise to drill a hole a...

Page 21: ...inner cone using a 1 Phillips screwdriver and the screws provided with the spinner 2 Stroke Installation Parts Required Wing panels left and right Micro servos with hardware 2 9 inch servo extension leads 2 Engines 2 Radio Throttle pushrods 2 Clevises 2 Silicone keepers 2 Engine Mounts 2 sets Fuel tanks 2 Hook and loop strap 2 Cowlings 2 Firewall drilling template 4 steel washers 16 8 steel washer...

Page 22: ...ch drill bit in a drill motor to enlarge the mounting holes Step 4 Use a cutoff wheel in a rotary tool to shorten one of the 6 32 Allen head machine screws to a length of 3 4 inches Also modify one 6 32 blind nut by removing one side of the flange as shown Step 5 Press the blind nuts into the mounting holes from inside the nacelle The modified blind nut is installed in the left mounting hole again...

Page 23: ...g 5 16 x 5 8 inches Step 10 Place a 6 steel washer onto each of the 6 32 Allen head machine screws Insert the screws and washers in the engine mounts noting that the modified screw locates in the lower of the two holes under the beveled edge of the right hand mount Step 11 Apply a drop of threadlock to each of the screws then use a 7 64 inch hex wrench to secure the mounts to the firewall Step 12 ...

Page 24: ...rews Slide a second 4 washer on each screw then thread on a 4 40 nylon locknut Use a 3 32 inch hex and 1 4 inch wrench to tighten the engine to the mount Step 16 Prepare a micro servo with grommets and bushings Note that the bushings are installed from the bottom of the servo Step 17 Attach a 9 inch servo extension lead to the servo and secure the connectors with dental floss Hint Apply a very sma...

Page 25: ...of the holes to strengthen the wood Allow the CA to cure without using accelerator Step 22 Feed the throttle servo lead through the hole in the spar and through the wing to the wing root Position the servo with the output shaft to the left hand side Use the hardware provided with the servo to install it with a 1 Phillips screwdriver Step 23 Insert an 11 3 4 inch hook and loop strap through the for...

Page 26: ...efore the cowl is installed Use your radio to move the throttle servo to the fully open position Move the pushrod forward to open the carburetor to the full open position and use a 1 Phillips screwdriver to secure the throttle pushrod in the EZ link Now use your radio to check operation of the throttle throughout its range and make any adjustments to the pushrod or servo travel volume as necessary...

Page 27: ...t Cowlings 2 Clear cowlings 2 Propellers 2 Spinners 2 2 x 1 4 inch woodscrews 8 Tools Required Ruler Felt tipped pen 1 Phillips screwdriver Rotary tool with cutoff wheel and drum sander Step 1 Use scissors to trim the clear cowling so it will fit over the fiberglass cowl Transfer the mounting holes to the clear cowl to serve as a reference Step 2 Cut openings in the clear cowling so that it can be...

Page 28: ... 7 16 inch screws Step 4 Shown here is the cutout for the muffler Use the nacelle cutout made in step 29 as a guide for the muffler opening in the cowling Step 5 Use a 1 Phillips screwdriver to install the cowling with four 2 x 1 4 inch woodscrews Rudder Hinging Parts Required Fuselage Rudder CA hinges 4 Tools Required T pins Thin CA Step 1 Prepare four CA hinges by inserting a T pin in the center...

Page 29: ...netrate the hinges completely Rudder Servo and Linkage Installation Parts Required Fuselage Servo with hardware 7 inch steel pushrod Small control horns 2 Copper sleeves 4 82 inch rudder cable Wire cable ends 2 EZ links 2 Radio M3 x 4 screws 2 Tools Required Felt tipped pen Pin vise 1 16 inch drill bit 5 64 inch drill bit Needle nose pliers 1 Phillips screwdriver Sidecutters Pencil Thin CA Ruler T...

Page 30: ...e holes Step 4 Place the servo in the radio tray in the upper fuselage and mark the mounting hole locations with a pencil Step 5 Remove the servo and use a 1 16 inch drill bit in a pin vise to drill the mounting holes Apply a drop of thin CA to each of the holes to strengthen the wood Allow the CA to cure without using accelerator Step 6 Use a 1 Phillips screwdriver and the hardware provided with ...

Page 31: ...n the left hand side of the rudder You may need to use a hobby knife to remove the covering from the cable exit hole in the fuselage Step 12 Remove the hatch from the right hand side of the rear fuselage and set it aside Fold the 82 inch rudder cable in half and use sidecutters to cut it into two 41 inch lengths Insert each cable into the guide tubes in the rear fuselage and feed them into the for...

Page 32: ...sleeves Step 17 Use you radio to check that the rudder servo is centered and center the rudder by aligning the balance tab at the top with fin Then use pliers to crimp the sleeves to the cables Trim the excess cable with sidecutters Any required cable tension adjustments can be made at the servo end Nose Gear and Steering Servo Installation Parts Required Fuselage Nose gear assembly 7 inch steel p...

Page 33: ... Remove the servo and drill the mounting holes with a 1 16 inch drill bit in a pin vise Apply a drop of thin CA to each of the holes to strengthen the wood Allow the CA to cure without using accelerator Hint Place a rag in the fuselage so that any drip of CA does not damage the windshield Step 6 Use a 1 Phillips screwdriver and the hardware provided with the servo to install it with the output sha...

Page 34: ...ep 10 Use a 5 64 inch drill bit in a pin vise to enlarge the center hole in the nose gear steering arm Step 11 Prepare the four 8 32 x 1 inch nose gear mounting screws by applying a drop of threadlock to the ends of the threads Step 12 Insert the steering pushrod into the center hole of the steering arm while placing the nose gear against the bulkhead Note that the anti torque scissor link faces f...

Page 35: ...Allow the CA to cure without using accelerator Step 16 Use a 1 Phillips screwdriver to install the hatch with four 2 x 1 4 inch woodscrews Main Landing Gear Installation Parts Required Fuselage Wing tube Wing struts left and right Landing gear left and right Wing panels left and right Landing gear fairings left and right 8 32 x 1 inch Allen head machine screws 6 Tools Required Low tack tape 1 8 in...

Page 36: ... tube in the fuselage Slide the wing panel onto the tube while guiding the end of the strut into the hole in the lower nacelle Slide the wing panel all the way against the fuselage and engage the strut end in its pocket under the outboard side of the nacelle This sets the strut in the correct location so the gear fairing can be glued in place Step 6 Apply a bead of canopy glue around the perimeter...

Page 37: ...r the screws then turn it counterclockwise to engage the screw heads in the keyhole slots in the nose cone bulkhead Step 3 Use a 1 Phillips screwdriver to install a 4 x 7 16 inch woodscrew in the lower left side of the cowling to retain it on the fuselage Receiver Battery and Switch Installation Parts Required Fuselage Receiver Battery Switch Y harness 3 9 inch extensions leads 2 36 inch extension...

Page 38: ...n leads and Y harnesses to the receiver Use the equipment list on page 4 as a guide for making these connections We recommend securing the elevator servo extension leads within the fuselage so that they cannot become entangled with the rudder cables Final Assembly Parts Required Fuselage Wing panels left and right Wing tube Wing struts Rear fuselage hatch Top fuselage hatch Stabilizer tube 8 32 x ...

Page 39: ... the leading edge and slide the stabilizer into place Step 5 Use a 1 16 inch drill bit in a pin vise to drill a hole through the stabilizer tube at the retaining screw location on the lower surface of each stabilizer half Do not drill all the way through the opposite side of the tube Step 6 Use a 1 Phillips screwdriver to install a 2 x 1 4 inch woodscrew in each side to retain the stabilizer halve...

Page 40: ...them to the fuselage Step 10 Set the top hatch in place on the fuselage and mark the mounting hole locations with a pencil Step 11 Use a 1 16 inch drill bit in a pin vise to drill the mounting holes in the fuselage Apply a small drop of thin CA to each of the holes to strengthen the wood Allow the CA to cure without using accelerator Step 12 Use a 1 Phillips screwdriver to install the hatch with f...

Page 41: ...he rudder should also move right Reverse the direction of the servo at the transmitter if necessary Step 2 Check the movement of the elevator with the radio system Moving the elevator stick toward the bottom of the transmitter will make the elevator move up Step 3 Check the movement of the ailerons with the radio system Moving the aileron stick right will make the right aileron move up and the lef...

Page 42: ...ropeller Check to make sure the propeller is tightly secured to the engine If not remove the spinner and use a wrench to tighten it If you have had any not so great landings you will want to inspect the propeller for any damage Small nicks and scratches can quickly become fractures causing the propeller to be unsafe for flight Always carry a few spare propellers so a damaged propeller can be repla...

Page 43: ...p maintain heading as the model transitions from flying speed to taxi speeds Elevator and Aileron dual rates should be adjusted for personal feel and also if there are any unusual wind conditions Age Requirements Age Recommendation 14 years or over This is not a toy This product is not intended for use by children without direct adult supervision Daily Flight Checks Step 1 Check the battery voltag...

Page 44: ...he Twin Otter really is It has a great speed envelope and is also capable of mild aerobatics such as loops and rolls We have also done extensive single engine performance testing with the Twin Otter Although it is a twin it actually can fly successfully on one engine and if you re skillful you can even shoot touches and goes with one engine running If you do happen to lose an engine in flight we r...

Page 45: ...ts all resulting liability If you as the Purchaser or user are not prepared to accept the liability associated with the use of this Product you are advised to return this Product immediately in new and unused condition to the place of purchase Law These Terms are governed by Illinois law without regard to conflict of law principals Safety Precautions This is a sophisticated hobby Product and not a...

Page 46: ...te disposal service or where you purchased the product Non Warranty Repairs Should your repair not be covered by warranty the repair will be completed and payment will be required without notification or estimate of the expense unless the expense exceeds 50 of the retail purchase cost By submitting the item for repair you are agreeing to payment of the repair without notification Repair estimates ...

Page 47: ... AMA Program Document 9 I will not operate my model aircraft while under the influence of alcohol or while using any drug which could adversely affect my ability to safely control the model 10 When and where required by rule helmets must be properly worn and fastened They must be OSHA DOT ANSI SNELL or NOCSAE approved or comply with comparable standards RADIO CONTROL 1 All pilots shall avoid flyin...

Page 48: ...33 horizonhobby com Hangar 9 com Printed 01 2010 16754 Horizon Hobby UK Units 1 4 Ployters Rd Staple Tye Harlow Essex CM18 7NS United Kingdom 44 0 1279 641097 horizonhobby co uk Horizon Hobby Deutschland GmbH Hamburger Strasse 10 25335 Elmshorn Germany 49 4121 46199 60 horizonhobby de ...

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