SIG Sun Dancer Assembly Manual Download Page 3

3

Cabane Struts:

2 Aluminum Cabane Strut Assembly

2 Aluminum Strut Fittings 

2 M3 x 15mm Socket-Head Bolts

4 M3 x 15mm Socket-Head Mounting Bolts

4 #3 Flat Washers

Interplane Wing Struts:

2 Interplane Struts

8 Aluminum Strut Fittings

8 4-40 x 3/8" Socket-Head Bolts

8 4-40 Lock Nuts

8 #4 Flat Washers

Tail Brace Wires:

2 Threaded Tail Brace Wires, 11-3/4" long

2 Threaded Tail Brace Wires, 10-1/8" long

4 Metal R/C Links

4 M2 Hex Nuts 

3 M2 x 19mm Phillips-Head Mounting Bolts

1 M2 x 25mm Phillips-Head Mounting Bolts

4 M2 Hex Nuts

Pushrods:

4 4-40 x 3" Threaded Pushrods; for ailerons

1 4-40 x 4" Threaded Pushrod; for right elevator

1 4-40 x 5-1/2" Threaded Pushrod; for left elevator

12 Metal R/C Links

12 4-40 Hex Nuts

12 Spring Keepers

1 4mm id x 460mm Outer Nylon Pushrod

1 3.2mm id x 460mm Inner Nylon Pushrod

2 M2.1 x 22mm Threaded Studs

2 Nylon Ball-Link Sockets

2 Metal Ball-Links

2 2-56 Hex nuts

Fuel Tank:

1 650 c (22 oz.) Fuel Tank

1 Rubber Stopper

1 Tie-Wrap

1 Metal Clunk Pickup

2 Aluminum Tubes

1 Fuel Tubing for inside tank

Miscellaneous:

4 1/2” x 13” Yellow Covering Strips

1 Sun Dancer Decal Set

1 Sun Dancer Assembly Manual

A NOTE ABOUT COVERING MATERIAL:
Your Sun Dancer has been professionally covered with Oracover

®

#33 Cad Yellow, #32 Golden Yellow, and #23 Ferrari Red. (Note:
In the United States, Oracover

®

is sold under the name of Hanger

9 Ultracoat

®

. The equivalent Ultracoat

®

colors are #872 Bright

Yellow, #889 Dark Yellow, and #866 True Red).

Oracover

®

is well known for its ease of application, lightweight, and

consistency of color. If you live in a dryer climate, you may notice
that some wrinkles might develop after removing the covered parts
from their plastic bags. If that is the case, there is no need to be
alarmed. The covering is not defective. This is perfectly normal
and nothing to do with the covering material or how it was applied.

It has to do with the moisture beneath the covering. Wood takes
on or loses ambient humidity. Your Sun Dancer ARF was 
manufactured in a 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 wrinkles that appear in the covering are easy to remove by
using a hobby-type of heat iron. We suggest covering the iron's
shoe with a thin cotton cloth, such as an old T-shirt to prevent
scratching the film. The iron should be set to about 280

O

- 300

O

F.

First use the heated iron to go over all the seams and color joints
in the covering, making sure they are all sealed and well adhered.
Then use the heated iron to lightly shrink material - do not press
on it. Once the covering is tight, lightly iron the material back down
to the wood. You can use a hobby type heart gun to re-shrink the
covering, but must be extra careful around the seams. Re-heating
the seams my cause them to "Creep", making them unsightly.

Modelers Tip: One of the most common problems associated
with shrinking any covering film is controlling the heat around the
seams. Heat applied close to or directly onto seams re-heats the
covering adhesive and the seams will often "crawl". This is easy
to control. Just tear a few paper towels into strips and soak them
in cool tap water. Lay the wet strips over any covering seam and
use a heat gun or iron as you normally would. The wet strips keep
the seam cool while the covering immediately next to it shrinks.
This tip works great with any iron-on covering.

REQUIRED TOOLS:
For proper assembly, we suggest you have the following tools and
materials available:

A selection of glues - SIG Thin, Medium, and Thick CA;

SIG Kwik-Set 5-Minute Epoxy, 
and Sig Epoxy (slow cure)

Threadlock compound, such as Loctite

®

Non-Permanent Blue

Screwdriver Assortment
Pliers - Needle Nose & Flat Nose
Diagonal Wire Cutters
Small Allen Wrench Assortment
Drill and assorted Drill Bits
Pen Vise for Small Dia. Drill bits
Hobby Knife With Sharp #11 Blades
Scissors
Covering Iron and Trim Seal Tool 
Masking Tape

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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