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         Construction Manual 

www.oldschoolmodels.com 

Page 13

Step 75 - Vertical Fin Assembly (FS3 & FS4)

Locate both FS3s and FS4s 

from BP9.

Just as you did with the vertical 

fin sheeting, glue one FS3 and 

one FS4 together to form a 

sheet for the rudder.

Make 2 of these.

Step 76 - Rudder Assembly (sheeting)

Glue one of the sheets from 

the previous step to the rudder 

framework.

Then remove the assembly, carefully 

sand it, then glue the other sheet 

over it to complete the rudder.

Step 77 - Elevator Assembly (CH2)

Locate two CH2s from LP7.

Glue one inside the cutout in the rudder 

sheeting as shown here, then flip the 

rudder over and do the same on the other 

side.

This completes assembly of the Kaos tail surfaces.

Now it’s time to start construction of the fuselage.

Prepare your work area

Now a fresh piece of waxed paper on your building board. You’ll 

also need the fuselage plans as a reference. No need to tape the 

side view down to the board as it's more for reference.

But you will need the top view later on in the build, so tape that 

part of the plan down.

Step 78 - Fuselage Assembly (F4 & TR4)

Locate F4 from LP3 and TR4 

from LP6.

Technically TR4 is symmetrical, 

side to side. But not front to 

back. Look for the etched 

circle that designates the 

front, starboard corner. Then 

glue F4 in place, by pushing it 

in from the top of TR4.

Make sure it's held at a 90° angle as the glue cures. (Remember 

those triangles?)

Step 79 - Fuselage Assembly (F3 & TR4)

Locate F3 from LP3.

This is attached to the front of 

TR4 (designated by the etched 

circle) as shown. Pay attention 

to the orientation. Again, make 

sure it's held at a 90° angle to 

TR4 as the glue cures. 

Step 80 - Fuselage Assembly (F5)

Locate F5 from LP5.

This is attached to the rear of TR4 

as shown here. Pay attention to 

the orientation. Again, make sure 

it's held at a 90° angle to TR4 as 

the glue cures. 

Step 81 - Fuselage Assembly (WH8)

Locate four WH8 from LP2.

These are stacked up, one on top of the 

other. Please use epoxy for this step, and 

clamp them together to make sure they 

are held perfectly in line as the glue cures.

Step 82 - Fuselage Assembly (FS1)

Locate FS1 from LP3.

This is the port side of the 

fuselage box. Dry fit this first, 

making sure you know where all 

the tabs are. It should fit flush 

against the three formers and 

TR4.

Note that there are extra long 

tabs on F3 and F5. These should stick out roughly 1/8" from above 

the outer surface of FS1.

When you know how it all works, remove the side and glue it in 

place. Make sure it is glued to each of the formers and TR4.

Step 83 - Fuselage Assembly (W8)

Locate the W8 assembly from a 

couple steps back.

This is inserted in the square 

hole towards the rear of FS1 as 

shown here. Lightly sand the tab 

on W8 as needed to get a good 

fit. Epoxy this in place.

Step 84 - Fuselage Assembly (TR2, TR3A & TR3B)

Locate the TR2 from LP4 and TR3A 

and TR3B from LP3.

Note the circle etched on TR2 and 

on TR3B. Flip TR2 over and glue 

TR3B to the top of the side with the 

circle (the shorter side). Then glue 

TR3A to the other side.

Make sure they line up properly as shown in the photo.

Step 85 - Fuselage Assembly (TR2 assembly)

Now the TR2 assembly from the 

previous step is installed into the 

front of the fuselage as shown here. 

You'll need to put a little pressure 

to bend the side (FS1) as needed 

for all of the tabs to completely seat 

in the slots. Glue this in position, 

noting that FS1 will need to curve in slightly to match up with the 

curvature of TR2.

Summary of Contents for Kaos

Page 1: ...atteries wheels etc throughout the building process You must correctly install all R C and other components so that the model operates correctly on the ground and in the air Installation shown in the...

Page 2: ...t 1 4 x 4 x 24 balsa 4 BP8 laser cut 1 16 x 4 x 24 balsa 2 BP9 laser cut 1 16 x 4 x 24 balsa 2 BP10 laser cut 1 16 x 4 x 24 balsa 2 BP11 laser cut 1 16 x 4 x 24 balsa 2 BP12 laser cut 1 16 x 4 x 24 ba...

Page 3: ...anual and online All photos shown in this manual are of different Kaos 60 prototypes Several pieces may have changed slightly with improvements we ve made so parts may look a little different in some...

Page 4: ...to the front and the rear jig dowels Make sure you slide them on in numerical order and pay attention to their orientation The etched rib number should be at the top when properly placed Group the R1...

Page 5: ...along the wing Step 9 Wing Assembly SW2 Locate two SW2s from LP1 and LP2 These are installed the same way as the previous SW pieces just doing it twice You are paying attention to where those etched...

Page 6: ...ood to get it to fit into the slots It is a tight fit Once you re satisfied with how it fits remove it then glue it in position to each rib and to where it contacts the upper portions of SW1 and SW2 M...

Page 7: ...apply a touch of upward pressure where the jig s dowels snap into the J2 and J4 jigs You should find that the dowels pop out and you re left with an assembly that can be flipped over Before popping th...

Page 8: ...ghtly sand the trailing edge so it will continue the airfoil shape Step 33 Wing Assembly dowels Now it s time to mark and drill the leading edge to accept the wing hold dowel Using the two 1 4 pre cut...

Page 9: ...it to length giving yourself a 1 4 or so extra on each end This is used as the bottom spar and will fit into the top cutout of each rib It is STRONGLY recommended that you dry fit this first You might...

Page 10: ...sure everything fits properly and the root ribs in each wing half are touching along their entire length when assembled into a single wing Take your time and get a good fit that doesn t require a lot...

Page 11: ...ding edge Next is to cut and install the leading edge pieces Check your scrap pile to see if you have the proper length first but if not use an uncut length of 1 4 x 1 2 x 36 balsa strip Glue these in...

Page 12: ...fore to complete the elevator halves Prepare your work area Now tape the vertical fin rudder plan and a fresh piece of waxed paper on your building board Step 69 Vertical Fin Assembly VF1 VF2 VF3 Loca...

Page 13: ...as the glue cures Step 80 Fuselage Assembly F5 Locate F5 from LP5 This is attached to the rear of TR4 as shown here Pay attention to the orientation Again make sure it s held at a 90 angle to TR4 as...

Page 14: ...form the fuselage side sheeting Refer to the diagram on the fuselage plan sheets on how these notch together You ll use the same techniques that you used when edge gluing sheeting together for the wi...

Page 15: ...osition but the middle of F2 should line up with the middle of the F2 on the plans Basically what we re looking for here is the fuselage to be lined up on the centerline of the plans as well as front...

Page 16: ...106 Fuselage Assembly stab supports Using scrap 1 4 square balsa cut 4 supports for the stab These will be glued where the stab contacts the inner surface of the fuselage sides You ll glue two on the...

Page 17: ...t works of art and match each other exactly Smooth out the edges of the fuselage Because of the 1 8 sheeting and the 1 8 basswood support installed around the fuselage s perimeter you can be a little...

Page 18: ...artially pushed up through the white mounting block Slip the steering arm in place then push the nose gear wire all the way through the arm and the block Stop when the wire is flush with the top of th...

Page 19: ...a bit of medium CA glue to permanently glue the joiner into both halves making sure the completed leading edge of the elevator is perfectly straight and flat Control horns servo pushrod installation...

Page 20: ...he entire airframe with the covering finish of your choice Note that if you re powering with an electric motor you ll need to make a hole for the cooling air to escape the bottom of the fuselage near...

Page 21: ...ans rather than making large changes electronically 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...

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