SIG Sun Dancer Assembly Manual Download Page 13

13

Slide a wheel collar onto the axle followed by a main wheel, and
then another wheel collar. Locate the outer wheel collar near the
end of the axle and snug its set screw tight against the axle. Now
slide the wheel and the inner wheel collar out against the outer
wheel collar, and lightly tighten the inner collar set screw. Trial fit
the fiberglass wheel pant in place over the wheel. If necessary,
reposition the wheel collars to center the wheel in the pant 
opening. Then tighten the set-screws for good.

Helpful Hint: Tighten all wheel collar set screws with their heads
pointing straight down. That way you will have easy access to the
collars if adjustments are needed.

28) Mount the formed aluminum main landing gear in place on

the fuselage using the three M4 x 15mm socket head bolts and flat
washers provided. Note that the blind nuts have been pre-installed
inside the fuselage for these bolts.

29) Locate the bag containing the tailwheel assembly. Hold the

short leaf spring in place on the fuselage. Make sure it is lined up
with the fuselage centerline, and that it is as far back as shown in
the pictures. Use a fine tip marker pen to mark the locations of the
3 mounting holes in the fuselage.

Drill the holes through the 

bottom of the fuselage with a 1/16" dia. drill bit.

30) Fasten the both leaf springs of the tailwheel assembly to the

bottom of the fuselage with three M3 x 15mm PWA screws. Note:
The tailwheel coiled springs will be installed later, after the fin and
rudder are attached to the fuselage.

31) Trial fit the fin & rudder onto the fuselage and make sure

you install the bottom hinge into the fuselage. Using a felt tip pen,
draw the outline of the rudder fairings onto each side of the fin and
around the fillet located on the front of the fin. Using a sharp #11
X-Acto

®

blade, cut just inside the previously made lines and

remove the covering material from both sides of the fin and the
small fillet section on the top of the fuselage. Again, you need a
good wood to wood contact for the best glue joint.

32) Using slow curing epoxy, apply a liberal amount to the 

bottom of the fin, insides of the rudder fairings, the fillet area on top
of the fuselage, and into the bottom hinge hole in the fuselage.
Slip the fin & rudder in place until it is fully seated in place and
secure with straight pins (you did install the lower hinge, didn't
you?). Wipe off any glue that has oozed out with a cloth soaked in
alcohol. Using a triangle, align the fin & rudder so it is 90

O

to the

horizontal stabilizer. Use long strips of masking tape to hold the fin
& rudder assembly in alignment until the glue cures. It is a good
idea to view the fin & rudder form the front and rear to make sure
it is aligned properly during the curing process.

Note: The tail brace wires are functional and must not be omitted.
Flying the model with out the brace wires could lead to structural
failure and loose control of the model aircraft.

33) Locate the bag that contains the tail brace wires. There are

a total of four tail brace wires - the upper tail brace wires measure
11-3/4" and the lower tail brace wires measure 10-1/4". They
come assembled with a half solder link on one end, and half a
threaded link on the other. Also included is a "jam" nut on the
threaded end of each of the brace wires. Pre-drilled hardwood
mounting points have been installed at the factory in each side of
the horizontal stabilizer, fin, and fuselage. Begin by removing the
covering from the holes in the hard points if needed. Adjust the
length of each brace wire so the tail surfaces are NOT pulled out
of alignment. Attach the tail brace wires as shown in the photo
with the threaded ends of the upper brace wires next to the fin, and
the threaded ends of the lower brace wires next to the fuselage.
Use the three M2 x 15mm  bolts and M2 hex nuts that have been
provided to attach the wires to the fin and stabilizer. Use the 
M2 x 25mm bolt and M2 hex nut to attach the lower brace wires to
the fuselage. When satisfied with the installation of the tail brace
wires, loosen each of the hex nuts and apply a small drop of thread
locking compound to the threads of the bolts and securely tighten
the hex nuts.

Summary of Contents for Sun Dancer

Page 1: ...unces of torque These servos or their equivalent from other manufactures can be relied upon to work well throughout the Sun Dancer s flight envelope A standard servo is adequate for the throttle Servo Arms We also suggest that you consider using after market reinforced plastic servo arms such as the Du Bro Super Strength products These output arms are available to fit any brand of servo They are v...

Page 2: ...rts from the plastic bags until needed during assembly All of the required parts screws and bolts will be included in the bag to assemble a particular component of the model Fuselage 1 Fuselage Tail Surfaces 1 Fin 1 Rudder 1 Stabilizer 1 Right Elevator 1 Left Elevator Hinges for above installed but not glued Hatch 1 Fuselage Hatch 4 T2 6 x 8mm PWA Screws Wings 1 Top Right Wing Panel 1 Top Right Ai...

Page 3: ... relatively humid region of the world The wood was therefore holding humidity at the time the parts were covered and bagged Once the parts are removed from their bags and subjected to drier conditions the wood quickly looses moisture and the covering may appear loose This also explains why most iron on covering stay tight in the summer only to loosen a little in drier winter conditions Any wrinkle...

Page 4: ... wing tip and allow the assembly to fully cure 3 After the glue has cured use one of the provided 1 2 x 14 Yellow Covering Strips to cover the bottom wing joint centering the covering over the joint Apply another strip to the top wing again centering the covering over the joint Work slowly and overlap the ends of the two strips by 3 8 at the leading and trailing edges Try to arrange the overlaps s...

Page 5: ...over the top bottom wing joint with the provided strips as show in Step 3 of this assembly manual 8 Note that a piece of string has been factory installed in each wing panel to make it easier to pull the servo wires and the attached extension cords through the openings in each wing panel Begin by attaching a 24 servo extension to each of the four the servos To prevent the connecting plugs from pul...

Page 6: ...m nut against the R C link and push the spring keeper in place over the R C Link Note Just tighten the jam nuts snuggly at this time further adjustments may be necessary during Final set up STABILIZER ELEVATOR ASSEMBLY 12 Hinge the elevators to the stabilizer in the same manner as in Step 4 The hinges are slightly smaller than the hinges used for the ailerons and require the use of a 3 16 drill bi...

Page 7: ...e open and free of any debris In addition remove the muffler carburetor and the spark plug form the engine a Slide the cowl over the engine and the fuselage until it is roughly in place making sure that the drive washer on the engine extends through the opening in the cowl A minimum of 1 16 clearance is required between the spinner backplate and the nose ring on the cowl Tack glue four small piece...

Page 8: ...that must be installed in the nose of the fuselage behind the firewall It must be close enough to the engine to allow the wiring to reach The module wiring consists of the spark plug lead the ground wire the electronic module connection to the prop hub sensor and the battery pack lead The battery pack lead stays in the fuselage and will be connected to a separate battery pack switch used to power ...

Page 9: ...n system and radio flight system as possible to prevent possible interference with the flight radio a We mounted our ignition battery to the inside of the hatch by gluing two pieces of 3 8 x 3 square basswood to the hatch using the dimensions shown in the photo Next drill four 3 32 holes in the basswood and thread in four J bolts Wrap the battery pack in foam and secure it to the hatch with two 64...

Page 10: ... so that the end of the housing is 1 2 past the fuselage former Glue the pushrod housing in place Trim off the excess pushrod housing leaving 1 of the pushrod housing protruding from the firewall After the outer pushrod housing tube is in place remount the engine permanently in place to the firewall Be sure to use thread lock compound on the bolt threads Attach the wiring leads to the engine 21 Th...

Page 11: ...ing it in place Cut off the excess short end of the cable Repeat this process to make the same type of end on the other piece of cable d Attach the rigging couplers to the servo put put arm as shown in the photo Make double sure that the cables do not cross over each other in the rear of the fuselage Each cable should be straight from the servo out put arm to the exit tube in the rear of the fusel...

Page 12: ...tab is square without leaning one way or the other Again measure from the center of the firewall to the tip of the stabilizer When satisfied pin the stab in place and allow the glue to cure BUILDER S TIP Use a sharpened piece of music wire or an awl to perforate the mating surfaces of the stabilizer and the fuselage These small holes or dimples allow epoxy glue to migrate into them and act like sm...

Page 13: ...d wood to wood contact for the best glue joint 32 Using slow curing epoxy apply a liberal amount to the bottom of the fin insides of the rudder fairings the fillet area on top of the fuselage and into the bottom hinge hole in the fuselage Slip the fin rudder in place until it is fully seated in place and secure with straight pins you did install the lower hinge didn t you Wipe off any glue that ha...

Page 14: ... with the hinge line of the rudder Hold the control horn in position and use a marking pen to mark the four base mounting hole locations onto the rudder Four 5 64 dia holes are now drilled through the rudder at the four marks just made Make sure you hold the drill perpendicular to the rudder when drilling these four holes Then bolt the two control horns in place using four M2 5 x 14mm 1 2 and four...

Page 15: ...one of the provided cabane struts into the rear position on the fuselage with two M3 x 15mm socket head bolts and flat washers b Next insert a 6 aileron extension cord into each of the front openings passing the extension between the fuselage sheeting and into the interior of the fuselage Make sure that the extension cord does not interfere with the hardwood mounting blocks for the aluminum cabane...

Page 16: ...Y harness to the bottom end of the 6 chord taped to the left cabane strut That completes the aileron hookups that remain inside the fuselage Later when bolting the bottom wing in place connect the unused end of the right aileron Y harness to the end of the 24 extension chord that you installed in the bottom right wing in step 8 Likewise connect the unused end of the left aileron Y harness to the 2...

Page 17: ...d attach the meter to the bottom wing next to the fuselage as shown in the photo This should also read 0O of incidence If not then look for the lead wires from the servos being caught between the wing and wing saddle or the wing improperly installed Now move the incidence meter to the center of the top wing View the top wing from the front and make sure the wing is close to horizontal level If nee...

Page 18: ...ter mixed with a very small amount of dish soap or SIG Pure Magic Model Airplane Cleaner or Fantastic Windex or 409 type cleaners all work good You will also need a supple squeegee the SIG 4 Epoxy Spreader SIGSH678 is perfect for this job a couple clean soft cloths old tee shirts are great a good straight edge a ruler and a hobby knife with a sharp 11 blade We also suggest that you have some trim ...

Page 19: ...nditions will help in correctly evaluating the flight performance of the model Begin your test flight by making sure the engine is properly set with a reliable idle a strong top end and smooth transition performance Set your engine s high speed needle valve a little on the rich side so that when the airplane noses up the engine will not be over lean and sag Holding up elevator taxi the model to ge...

Page 20: ...e of the huge control movements available from this model However we would urge you to sneak up on such control throws making very sure you have them available to you only on your high rate switches We hope you will enjoy your SUN DANCER for a long time to come Please fly the model safely with constant regard to other fliers spectators and property GOOD LUCK AND SAFE FLYING ...

Page 21: ...del size or full size are not toys Because of the speeds that airplanes must achieve in order to fly they are capable of causing serious bodily harm and property damage if they crash IT IS YOUR RESPONSIBILITY AND YOURS ALONE to assemble this model airplane correctly according to the plans and instructions to ground test the finished model before each flight to make sure it is completely airworthy ...

Page 22: ... providing the most power at a reasonable cost First Place Engines are your best choice for large gasoline powered model airplane power plants All engines use piston and cylinder assemblies from world renowned manufacturers such as Husqvarna and Sachs Makita insuring long life and easy operation Using state of the art CNC machines First Place produces all other major components from high quality b...

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