Stevens AeroModel Build It! FullHouse 500 Build Instructions Download Page 1

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FullHouse 500

Electric Aileron Trainer Kit

Wing Span:

50 inches |

Wing Area:

455 square inches

Average Flying Weight:

26 ounces

Build Instructions -

Version 1.0 (revised 04.15.2014)

Build Instructions

Page 1

Summary of Contents for Build It! FullHouse 500

Page 1: ...r Kit Wing Span 50 inches Wing Area 455 square inches Average Flying Weight 26 ounces Build Instructions Version 1 0 revised 04 15 2014 Build Instructions FullHouse 500 Build Instructions 2012 Stevens...

Page 2: ...kit immediately in new and unused condition to the place of purchase THIS PRODUCT IS NOT INTENDED FOR CHILDREN 12 YEARS OF AGE OR YOUNGER WARNING This product may contain chemicals known to the state...

Page 3: ...aser cut from SH655 1 3 16 in x 3 3 4 in Dowel 1025 2 3 16 in x 2 in Dowels 1022 2 Du Bro RC 936 Razor Control Horns 1 pkg DUB936 4 Du Bro RC 845 Mini E Z Connectors 2 pkg DUB845 4 Du Bro RC 139 1 8 i...

Page 4: ...genuine AeroFILM brand model airplane covering film The lower working temperature and superior shrink of AeroFILM and AeroLITE are especially desirable for those new to covering model airplanes AeroL...

Page 11: ...nterlocks like a 3D puzzle we suggest that when fitting parts you dry fit use no glue the parts together first It s advised to work 1 2 steps ahead in the instructions using this dry fit technique whi...

Page 12: ...tire structure square and true 1 Assemble the Central Crutch from parts F1a and F1b Bond with thin CA 2 Assemble two side rails F2 from parts F2a and F2b Bond with thin CA 3 Fit side rails F2 to Left...

Page 13: ...Instructions 2012 Stevens AeroModel All rights reserved Page 13 Step 1 Step 2 Step 3 Step 4 Step 8 Step 7 Step 6 Step 5 F1a F1b F2a F2b F1 F2 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11a F11b F11c F11 F3 F4 F5 D...

Page 14: ...ing in the corner created by former F7 the central crutch and the side rail 15 Follow steps 13 and 14 to dry fit F15a and F15 b between formers F8 and F9 16 Follow steps 13 and 14 to dry fit F16a and...

Page 15: ...tructions 2012 Stevens AeroModel All rights reserved Page 15 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 F12 F13 F13 F7 F14 15 16a F8 F7 F7 F8 F8 F9 F15a F15b F16a F16b F9 F10 F4 F5...

Page 16: ...d bent sides to dry When the sides have dried thoroughly tack glue them to the fuselage formers with medium CA glue 21 Fit the wing saddle F21 to the tabs on top of formers F4 F5 F6 and the spine F13...

Page 17: ...ructions FullHouse 500 Build Instructions 2012 Stevens AeroModel All rights reserved Page 17 Step 17 Step 17 Step 18 Step 19 Step 22 Step 23 Step 21 Step 20 F17 F19 F18 Scrap F20 F7 F21 F22 F23 F24 Th...

Page 18: ...ined block DO NOT BOND 30 Use the longer of the 3 16 in diameter dowels supplied with your kit as a jig to assist with the installation of the Rear Wing Dowel Mounting Block Slide the dowel through th...

Page 19: ...vens AeroModel All rights reserved Page 19 Step 24 Step 24 Cont Step 25 Step 26 Step 27 Step 28 Step 29 Step 30 F23 F25 F24 F25 F26 F27 F28 F29a F29b F29c 3 16 in dowel 3 16 sq stringer 3 16 sq string...

Page 20: ...fuselage assembly is now complete go feed the dog a biscuit he deserves it then when you get back turn the fuselage up side down and continue with the construction of the bottom half 33 Fit and tack g...

Page 21: ...500 Build Instructions 2012 Stevens AeroModel All rights reserved Page 21 Step 31 Step 32 Step 33 Step 34 Step 35 Step 36 Step 37 Step 38 F27 3 16 sq stringer F30 F30 F31 F32 F33 F30 F33 F33 F34 LEFT...

Page 22: ...k thin CA around the edges of the doubler to bond it to the fuselage crutch and former F30 43 Follow the procedures in step 42 to fit and bond doublers F42 and F43 to the inside face of doublers F40 a...

Page 23: ...00 Build Instructions 2012 Stevens AeroModel All rights reserved Page 23 Step 39 Step 40 Step 41 Step 42 Step 43 Step 43 Cont Step 44 Step 45 F35 F36 F37 F38 F39 F40 F41 F40 F41 F42 F43 F42 F43 F8 F9...

Page 24: ...hatch doubler immediately in front of former F34 Wick medium CA between the brace and the fuselage sides doublers and former F34 50 Fit the keel F46 to the bottom of the rear formers Key the tab at t...

Page 25: ...oModel All rights reserved Page 25 Front Gear Block 2 1 2 in 2 1 8 in Rear Gear Block Step 46 Step 47 Step 48 Step 49 Step 50 Step 50 Cont Step 51 Step 51 Cont F r o n t G e a r B l o c k F30 F34 R e...

Page 26: ...the stringers to formers F34 F35 and F36 Lightly press the aft end of the stringers down until the no longer stand proud of the outer stringers and the central keel Bond the ends of the stringers to f...

Page 27: ...age 27 Step 52 Step 52 Cont Step 53 Step 53 Cont Step 54 Step 55 Step 56 Step 56 Cont F34 F34 F37 Terminate forward of F37 Fuselage Stringer Fuselage Stringer Fuselage Stringers Fuselage Stringers F47...

Page 28: ...ges to bond F51 to the fuselage doublers and F30 61 Place the ply motor mount F52 front side down on the building table Using a small hammer seat the four 4 40 blind nuts into the back of the motor mo...

Page 29: ...Instructions 2012 Stevens AeroModel All rights reserved Page 29 Neo Magnet Step 57 Step 58 Step 59 Step 59 Cont Step 60 Step 61 Step 62 Step 63 F34 F30 F30 F50 F51 F52 F52 F52 F53 Back Front Bottom Vi...

Page 30: ...ond parts F55 F56 F57 the fuselage doublers motor mount and former F30 67 Fit and bond F58a F58b and F58c together to form the F58 nose sheeting 68 Moisten both surfaces of F58 with glass cleaner to s...

Page 31: ...ons FullHouse 500 Build Instructions 2012 Stevens AeroModel All rights reserved Page 31 F55 F56 F57 F56 F57 F58a F58c F58 F58 Sharp Round Step 64 Step 65 Step 66 Step 67 Step 70 Step 69 Step 68 Cont S...

Page 32: ...instructions to exit through F47 above Note that tubing should cross just aft of former F36 72 Once satisfied that the pushrod housings have been properly fit bond the housing within the balsa formers...

Page 33: ...lHouse 500 Build Instructions 2012 Stevens AeroModel All rights reserved Page 33 Step 71 Step 71 Cont Step 72 Step 73 Step 74 Step 75 Step 76 Step 77 H1 H2 H3 Front Front H4 H5 H6 H7 F36 F37 F48 TRIM...

Page 34: ...rly seated and fit within the hatch center spine test fit the spine part within fuselage be certain that the arrow on the H5 spine points to the front of the fuselage and verify that the magnets do in...

Page 35: ...structions 2012 Stevens AeroModel All rights reserved Page 35 Step 78 Step 79 Step 80 Step 81 Step 82 Step 83 Step 84 Step 81 Cont H6 H8 H9 H10 H10 H1 H5 H2 Hatch Stringers H2 Aft H7 Neo Magnet Neo Ma...

Page 36: ...the rudder over Detail Sheet 1 of 2 from parts R1 R2 R3 R4 R5 R6 and R7 Do not sand the rudder at this time 88 Use the short length of 1 16 in wire to scrape out the etched area at the base of the lef...

Page 37: ...s FullHouse 500 Build Instructions 2012 Stevens AeroModel All rights reserved Page 37 Step 85 Step 86 Step 87 Step 88 Step 89 Step 90 Step 91 Step 92 H11 H11 Aft H9 V1 V2 V3 V4 A A B C C D A B A B R1...

Page 38: ...position wipe away any excess glue that oozes out and retain pressure on parts until the glue has set 97 Turn the rudder over and repeat the process given above in steps 95 and 96 to install the seco...

Page 39: ...Stevens AeroModel All rights reserved Page 39 Step 93 Step 94 Step 95 Step 96 Step 97 Step 98 Step 99 Step 100 R9 R8 R8 C D A B E A E LEFT RIGHT Horn used for alignment DO NOT BOND H1 H2 H5 H4 H6 H9 H...

Page 40: ...t cannot adequately be retained with friction Notes on tack glueing parts When parts cannot easily be retained with friction use a single tiny drop of medium CA glue applied sparingly through a CA glu...

Page 41: ...012 Stevens AeroModel All rights reserved Page 41 E7 Step 101 Step 102 W1b W1a W1c W2b W2a W3 W3 W4 W5 W4 W3 W1 W2 Step 103 Step 104 Step 105 Step 106 Step 107 Step 108 CENTER W1c on the BACK of the s...

Page 42: ...ing edge gusset W9 to the trailing edge W8 and rib W3 113 Fit and tack glue the leading edge web W10 to the front of all ribs Note The arrow at one end of W10 will point to the center of the wing and...

Page 43: ...500 Build Instructions 2012 Stevens AeroModel All rights reserved Page 43 Step 109 Step 110 Step 111 Step 112 Step 116 Step 115 Step 114 Step 113 W5 W6 W6 W7 W8 W8 W9 W10 W11 W3 W4 W4 W12 W5 W5 W13 W...

Page 44: ...inal bond the wing by wicking medium CA around all mating surfaces of the wing panel as completed to this point Repeat steps 106 through 120 marked with a double check box to build the right wing half...

Page 45: ...AeroModel All rights reserved Page 45 Step 117 Step 118 Step 119 Step 120 Step 121 Step 122 Step 123 W6 W7 W14 W3 W11 W15 W16 W3 W11 W24 W25 W26 W27 W4 W1 W17 W18 W20 W22 W19 W21 W23 W5 W7 W6 W2 DO NO...

Page 46: ...notch in the center of the W1 main spar Nest the spar cap within the notches atop each rib and the notch in the wing tip sheeting Turn the wing over ensure there are no gaps between spar cap and main...

Page 47: ...012 Stevens AeroModel All rights reserved Page 47 Step 125 Step 126 Step 127 Step 128 Step 132 Step 131 Step 130 Step 129 W28a R W28b R W28c R W28 L W28 L W28 L W29a W29b W29 W1 W30 W31 W30 W31 W32 W3...

Page 48: ...ond re visit any previously tack glued spots with medium CA glue to thoroughly bond parts within assembly Don t neglect critical areas such as those between the ribs and spar and spar to cap strips en...

Page 49: ...2012 Stevens AeroModel All rights reserved Page 49 Step 133 Step 134 Step 135 Step 136 Step 137 Step 138 Step 139 Step 140 W35 W36 W37 Top B o t t o m A1 A2 Left Aileron A1 A3 W3 W3 W1 W5 Bottom View...

Page 50: ...eron will point left Take your time dry fit or tack glue all the parts Compare the right aileron with the completed left aileron to make sure you are not building two of the same side before bonding a...

Page 51: ...House 500 Build Instructions 2012 Stevens AeroModel All rights reserved Page 51 Step 141 Step 142 Step 143 Step 144 Step 146 Step 145 A1 A4 A5 A1 A5 A1 A6 A2 A7 A6 A1 A5 A7 A6 A8 A8 A2 Step 147 Step 1...

Page 52: ...ar wing dowel mounting block Center the dowel within the block with equal lengths extending from both sides Bond with medium CA 155 Solder an appropriate battery connector to your 30A ESC Now connect...

Page 53: ...uctions 2012 Stevens AeroModel All rights reserved Page 53 Step 149 Step 150 Step 151 Step 152 Step 155 Step 154 Step 156 Step 153 Two Each Gear Leg Exit Open Hole 2 in Dowel 2 in Dowel 3 4 Inch 30A E...

Page 54: ...channels on your receiver and center the trims for these channels Disconnect the servos and mount them within the fuselage as shown Mount the control horns so that they extend in opposite directions...

Page 55: ...ructions 2012 Stevens AeroModel All rights reserved Page 55 Step 157 Step 158 Step 159 Step 160 Step 161 Step 162 Step 163 Step 164 LEFT Washers 3 16 in Drill 1 16 in Mini E Z Connector DUB845 1 32 Wi...

Page 56: ...e so that there is an equal margin all around the window openings in the fuselage sides When you are satisfied with the positioning of the windscreen hold it in place with several small pieces of mask...

Page 57: ...s AeroModel All rights reserved Page 57 Step 165 Step 166 Step 167 Step 168 Step 169 Step 170 Step 171 Step 172 3 in Lite Wheels DAV5530 Wheel Collar DUB139 32 Rubber Band Acetate Windscreen F O L D F...

Page 58: ...he Elevator and Rudder pushrods to the control horns with the supplied nylon Micro E Z Links DUB26310 Note See the Detail Sheet 1 of 2 for instruction on making silicone safety rings for the E Z Links...

Page 59: ...evens AeroModel All rights reserved Page 59 Step 173 Step 174 Step 175 Step 176 Step 177 Step 178 Step 179 Step 180 Washer 3 4 in Tail Wheel Square Tape Hinge Control Horn Bottom View Bottom View Aile...

Page 60: ...p with the control horn on the aileron 185 Cut a 4 in length of 1 32 in wire and make a 90 degree bend about 3 16 in from one end as you did for the Rudder and Elevator pushrods Slide the pushrod thro...

Page 61: ...Instructions 2012 Stevens AeroModel All rights reserved Page 61 Step 181 Step 182 Step 183 Step 184 Step 185 Step 186 Step 187 Step 188 TRIM TRIM Bottom View Bottom View Bottom View Leading Edge Trail...

Page 62: ...style prop adaptor supplied with the motor kit Re install your battery hatch and ready for pre flight Congratulations Your Stevens Aero FullHouse 500 is finished Clean up your mess and take the wife...

Page 64: ...lpful at avoiding disaster While not an exhaustive pre flight check these are some of the major items that you should consider using when developing your own pre flight check list Get in the habit of...

Page 65: ...You ve completed your first flight s on your Stevens Aero FullHouse 500 By now you ll have noticed that the FullHouse 500 is a very stable airplane When built straight and trimmed for level flight th...

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