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Use a razor plane or sanding bar to knock  the 

point  off  of  the  leading  edge  square  stock.  

Remove only enough  material from the point 

to bring it flush with the center section LE1.

Use a long  sanding bar  loaded with 250 and 

400  grit  paper  to  round  out  leading edge  to 

match wing saddle of fuselage.

Use sanding block to taper SR1b to match rib.

Carefully  remove  material.    Tip:  protect 

surrounding spar  and ribs  from sanding block 

action  with masking tape.

Properly tapered servo pocket.

Sand remainder of wing surface with 400 grit 

paper on a large sanding block  in preparation 

for  covering.    Remove  only  enough material 

to eliminate  the light  brown  “laser  burn”  and 

smooth out any raised grain.

© 2009 Stevens AeroModel all rights reserved. 

Page 24 of 30

Summary of Contents for XS480

Page 1: ...XS480 axis By Stevens AeroModel Length 41 inches Span 47 inches Area 485 inches2 Flying Weight 24 oz Version 09 29 2009 2009 Stevens AeroModel all rights reserved Page 1 of 30...

Page 2: ...pared to accept the liability associated with the use of this product the buyer is advised to return this kit immediately in new and unused condition to the place of purchase THIS PRODUCT IS NOT INTEN...

Page 3: ...fuel tubing EZ link retainer 2 Wheel retention washers press on wheel collar 2 3 16 in Neo Magnet 2 4 40 x 3 8 in nylon machine screw 4 4 40 x 3 8 in Machine Screw steel for motor mount 6 4 40 blind...

Page 4: ...barrier between your worktable and the product assembly Promptly clean up any epoxy spills with rubbing alcohol and a disposable towel Bonding the assembly As this product tabs notches and otherwise i...

Page 5: ...ne side of the F1 firewall Retain with thick CA glue around edge of nut Key F1 firewall to the front of F0 center crutch with flange portion of blind nut facing aft Assemble each of the two fuselage s...

Page 6: ...ble the top F7 and bottom F8 fuselage formers from sub assemblies F7a F7b and F8a F8b respectively Fillet interior joints along fuselage sides and former F1 F0 with medium CA glue then install glue to...

Page 7: ...along lower edge of F15 Build bond together former F11 from sub assemblies F11a F11b Install blind nuts to completed F11 former and retain with medium CA glue Study photo below then install F11 and F...

Page 8: ...uselage assembly as illustrated Install formers F4 and F5 within fuselage assembly Square fuselage to worktable and tack glue at tab and notch locations Install optional servo pocket ply doublers F3 t...

Page 9: ...e tabs in H1d should extend proud of underside of H1d by 1 16 in Using thick CA glue bond H1 on top of H2 using tabs from H1d to locate H1 atop H2 Glue one 3 16 in diameter magnet within locating hole...

Page 10: ...g Installation Locate the push rod sleeves included in your DUB922 pushrod system and pass through holes in formers F3 and F4 Route pushrod sleeves through former F5 then cross then pass through F6 as...

Page 11: ...4a Nest bent end of wire in channel of F14b and retain with medium CA glue Using thick CA glue laminate F14c on top of F14b Once glue has cured straighten wire where it exits plywood then bend down at...

Page 12: ...400 grit sanding block in preparation for covering Assemble Tail Feathers Assemble vertical stabilizer rudder horizontal stabilizer and elevator halves Using the plan set as a guide assemble each com...

Page 13: ...t to rudder elevator and horizontal stabilizer assemblies Aileron Assembly Assemble a right and left aileron using the plan set as a guide Assemble each component beginning with the outer framework an...

Page 14: ...two more 1 8 in x 1 4 in x 24 in balsa sticks to create one lower spar Tip Use straight edge to align lengths of wood to be joined to insure accurate alignment See the detail on the plan sheet How to...

Page 15: ...r jig and spans between R2 ribs across center of wing section Carbon is captured by S1 jig and R1 R2 ribs Flatten wing against work surface inspect all parts to ensure proper fit then tack glue assemb...

Page 16: ...ack glue top spar where it intersects wing ribs Bond SW1 shear web between R1 ribs top and bottom spar forward of spar jigs Align R1a with notches in R1 then use thick CA glue to laminate R1a to insid...

Page 17: ...together two 1 8 in x 3 16 in x 24 in balsa sticks Cut joined sticks to 43 in length and install spanning wing assembly Note that sub spar will seat against notch in wing wing tip as indicated below B...

Page 18: ...g thick CA glue laminate W4 to recess in T1 at wing trailing edge Fit and tack glue all SW2 vertical grain shear webbing in between ribs and sub ribs spanning R1 through R4 Webbing is notched on one s...

Page 19: ...f wing Remember turbulators sit 3 32 in proud of interior ribs and flush with ribs R1 and R5 Flatten wing against your building surface then glue turbulator stock at each contact point with ribs With...

Page 20: ...h wing saddle of fuselage Use sanding block to taper SR1b to match rib Carefully remove material Tip protect surrounding spar and ribs from sanding block action with masking tape Properly tapered serv...

Page 21: ...del fund P O Box 15347 Colorado Springs Co 80935 Remove taped parts from work table Now invert assembly and with freshly taped surface facing down fold parts back to align beveled edge of movable surf...

Page 22: ...all HS 65 servos within fuselage using hardware provided with servo Use radio or servo tester to electronically center servos Install control horns to servos then pass pushrods through housing from ta...

Page 23: ...ded with pushrod kit Cut the three 3 provided 3 16 in dia dowels to 4 1 4 in length and install centered within fuselage assembly Retain dowels using medium CA glue Install a 6 in strip of sticky back...

Page 24: ...SC to inside edge of fuselage using hook and loop tape not provided Open up hole in W6 former of wing to allow servo wires to pass through Remove covering over servo pockets Prepare long servo control...

Page 25: ...unt HS 65 servos using hardware provided with servo Aileron servo wire should pass through opening in W6 at bottom of wing Use plan set as a guide to bend up two aileron control rods from provided 045...

Page 26: ...xtend back to 3 1 2 in from leading edge move CG back slowly as you become comfortable with flight performance Control Surface Travel given in degrees and set with protractor gauge Ailerons Low Rate 1...

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