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membership  is  required  to  fly  at  AMA  sanctioned  clubs.
There are over 2,500 AMA chartered clubs across the country.
Among  other  benefits,  the  AMA  provides  insurance  to  its
members who fly at sanctioned sites and events. Additionally,
training programs and instructors are available at AMA club
sites to help you get started the right way. Contact the AMA
at the address or toll-free phone number below:

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302-9252

Tele. (800) 435-9262

Fax (765) 741-0057

Or via the Internet at:

http://www.modelaircraft.org

In addition to common household tools and hobby tools, this
is  the  “short  list”  of  the  most  important  items  required  to
build the Tower Hobbies Kaos .40. 

Tower Hobbies Build-it

CA and Epoxy glue are recommended.

HARDWARE & ACCESSORIES

Four-channel radio with four standard servos. 

The recommended engine size range for the Tower Kaos
.40 is .40 - .46 cu in [6.5 - 7.5cc] two-stroke or .48 - .70
cu in [8 - 11.5] four-stroke. 

6" [150mm] servo extension (HCAM2701 for Futaba

®

)

1/4" [6mm] R/C foam rubber (HCAQ1000)

3' [900mm] standard silicone fuel tubing (GPMQ4131)

2 oz. Tower Hobbies Build-it Thin CA (TOWR3800)

2 oz. Tower Hobbies Build-it Medium CA+ (TOWR3801)

Tower Hobbies Build-it 30-minute epoxy (TOWR3811)

Drill  bits:  1/16"  [1.6mm],  5/64  [2mm],  3/32"  [2.5mm],
5/32" [4mm]

T-pins (HCAR5100)

#1 Hobby knife (TOWR1010)

#11 blades (5-pack, TOWR1015)

OPTIONAL SUPPLIES & TOOLS

Stick-on segmented lead weights (GPMQ4485)

Top Flite

®

MonoKote

®

trim seal iron (TOPR2200)

Top Flite MonoKote heat gun (TOPR2000)

2 oz. Tower Hobbies spray CA activator (TOWR3804)

Masking tape (TOPR8018)

Threadlocker

thread-locking cement (GPMR6060)

Denatured alcohol (for epoxy clean up)

AccuThrow

Deflection Gauge (GPMR2405)

CG Machine

(GPMR2400)

Robart Super Stand II (ROBQ1402)

When  you  see  the 

term  test

fit  in  the  instructions,  it

means that you should first position the part on the assembly

without using any glue

, then slightly modify or 

custom fit

the

part as necessary for the best fit.

Whenever  the  term 

glue

is  written  you  should  rely

upon  your  experience  to  decide  what  type  of  glue  to  use.
When a specific type of adhesive works best for that step, the
instructions will make a recommendation.

Whenever just 

epoxy

is specified you may use 

either

30-minute  (or  45-minute)  epoxy 

or

6-minute  epoxy.  When

30-minute epoxy is specified it is 

highly

recommended that

you use only 30-minute (or 45-minute) epoxy, because you
will need the working time and/or the additional strength.

Photos

and 

sketches

are  placed 

before

the  step  they

refer to. Frequently you can study photos in following steps
to get another view of the same parts.

Before starting to build, take an inventory of this kit to make
sure it is complete, and inspect the parts to make sure they
are of acceptable quality. If any parts are missing or are not
of  acceptable  quality,  or  if  you  need  assistance  with
assembly, contact 

Order Assistance

. When reporting defective

or missing parts, use the part names exactly as they are written
in the 

“Ordering Replacement Parts”

section on this page.

Order Assistance:

Telephone: (800) 637-6050

Fax: (217) 398-7721

E-mail: 

[email protected]

Replacement parts are available from Tower Hobbies for your
Tower Kaos .40 ARF. Our order assistance representatives are
ready  to  answer  or  place  your  order.  Call  us  at  (800)
637-6050.

Replacement Parts

Wing Set - TOWA6010

Fuselage Set - TOWA6011

Tail Set - TOWA6012

Landing Gear Set - TOWA6013

Canopy - TOWA6014

ORDERING REPLACEMENT PARTS

KIT INSPECTION

IMPORTANT BUILDING NOTES

ADDITIONAL ITEMS REQUIRED

3

Summary of Contents for TOWA2052

Page 1: ...he act of using the user assembled product the user accepts all resulting liability If the buyer is not prepared 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 READ THROUGH THIS MANUAL COMPLETELY BEFORE STARTING CONSTRUCTION IT CONTAINS IMPORTANT INSTRUCTIONS AND WARNINGS CONCE...

Page 2: ... a few cases the instructions may differ slightly from the photos In those instances the written instructions should be considered as correct 3 You must take time to build straight true and strong 4 You must use an R C radio system that is in first class condition and a correctly sized engine and components fuel tank wheels etc throughout the building process 5 You must correctly install all R C a...

Page 3: ...ccuThrow Deflection Gauge GPMR2405 CG Machine GPMR2400 Robart Super Stand II ROBQ1402 When you see the term test fit in the instructions it means that you should first position the part on the assembly without using any glue then slightly modify or custom fit the part as necessary for the best fit Whenever the term glue is written you should rely upon your experience to decide what type of glue to...

Page 4: ...arge 1 3 x 10mm Phillips head machine screws 12 3 x 5mm Phillips head machine screws 6 4mm Blind nuts pre installed in the firewall and wing bolt mounting plate 3 560mm Plastic pushrod tubes pre installed in fuselage 2 356mm Plastic pushrod tube 3 2 x 680mm Pushrod wire threaded one end 1 2 x 400mm Pushrod wire threaded one end 1 405mm Wire pushrod with Z bend on one end 2 2 x 155mm Pushrod thread...

Page 5: ...four of the circular hinge material disks Look closely at the disk and you will see a slit cut through the center of the disk This slit will aid in wicking the glue into the hinge It is important that the slit in the disk runs perpendicular to the control surface Insert a pin through the middle of each hinge disk just off of the slit Test fit the ailerons to the wing with the hinges installed 4 Re...

Page 6: ...oth wing halves Clamp the leading edge of the wing and use masking tape to hold the wing together until the epoxy has cured Be certain the leading and trailing edges of both wing halves accurately align 4 Using a felt tip pen mark a box 1 3 4 x 2 3 8 44 x 60mm 5 Cut through the sheeting on the lines you have drawn with a hobby knife Remove the sheeting 6 Locate the die cut plywood servo tray and s...

Page 7: ...osition be sure that the plate is set back 1 8 3mm from the trailing edge of the wing Once the glue has cured use a 5 32 4mm drill bit to drill through the wing bolt holes from the top of the wing through the wing bolt plates 11 Temporarily bolt the wing to the fuselage with two 4 x 40mm bolts and two 4mm washers 12 Locate the wing belly pan Cut the covering away from the holes at the rear of the ...

Page 8: ...ure it is aligned with the fuselage Once the glue has cured remove the wing from the fuselage INSTALL THE MAIN LANDING GEAR 1 Cut the covering away from the landing gear blocks on both wing panels 2 Insert the landing gear wires into the holes in the landing gear blocks The short end of the wire is the end that is inserted into the landing gear block Do this for both wings 3 Locate two nylon landi...

Page 9: ...remove a servo screw into each of the holes Put a couple of drops of thin CA into each of the holes and allow the glue to cure Permanently install the servo using the screws provided with the servos 2 Locate two nylon aileron torque rod links Thread them onto the aileron torque rods approximately 20 full turns 3 Locate the two 6 152mm aileron pushrod wires Install a nylon clevis onto the threaded ...

Page 10: ...stab until the distance is equal Once the stab is positioned properly use a felt tip marker to mark the outline of the fuselage on the bottom of the stab 4 Stand five to ten feet 2m behind the model and view the stab and wing If the stab and wing align with each other proceed to the next step If the stab and wing do not align remove the stab and sand the high side of the fuselage until the stab al...

Page 11: ... slots The lower hinge on the rudder does not have a matching slot on the bottom of the fuselage Mark the location for the hinge slot on the bottom of the fuselage Using a hobby knife cut a hinge slot where you have marked 11 Permanently install the rudder to the fin and fuselage using the same technique used for installing the ailerons and elevators 12 Center the canopy on the top of the fuselage...

Page 12: ...firewall using two 4 x 15mm machine screws 3 Install the engine mount to the firewall with four 4 x 15mm machine screws 4mm lock washers and 4mm flat washers 4 Locate one of the two 14 356mm white nylon pushrod tubes Roughen one end of the tube with 220 grit sandpaper Insert the un sanded end of the tube into the hole in the bottom left side of the firewall Feed the tube through the fuselage so th...

Page 13: ... nylon steering arm and into the bottom of the engine mount Apply a drop of threadlocker to the set screw Then tighten the set screw in the steering arm onto the flat spot on the landing gear wire 10 File a flat spot onto the end of the metal nose gear wire 11 Locate two 4mm wheel collars and two 3 x 5mm set screws Install the screws into the wheel collars Slide a wheel collar and set screw onto t...

Page 14: ...r enlarge the cut outs that are already made in the engine compartment Make the necessary adjustments as needed to allow your engine to fit 6 Locate the plastic spinner Remove the nut and washer from the engine crankshaft and slide the spinner onto the crankshaft Place the engine on the engine mount positioning it so that there is a least 1 8 3mm clearance between the back of the spinner and the s...

Page 15: ... 1 Install your servos into the servo bay using the hardware and instructions that came with the servos Install the servos in the direction shown You will only need to use a servo arm that has three holes in the arm If your servo arms have more than 3 holes cut off the excess holes and shape the end of the arm to a round finish with a sanding block or high speed rotary tool Cut off the unused arms...

Page 16: ...ock connector the 3 x 5mm set screw connector and the knurled nut Remove the servo arm from your throttle servo Drill the outermost hole of the servo arm with a 5 64 2mm drill bit Install the connector by inserting the threaded pin into the servo arm IMPORTANT Place a drop of Threadlocker onto the threads Install the knurled nut onto the threads but do not tighten it against the servo arm It is ne...

Page 17: ...er the servo and then tighten the set screw against the pushrod wire 11 Center the rudder Place the rudder pushrod over the outermost hole in the servo arm Using a fine point marker make a mark on the pushrod where it crosses over the hole in the servo arm Bend the pushrod 90 degrees on the mark Cut the pushrod so that it extends 3 8 9 5mm above the bend Drill the outermost hole of the servo arm w...

Page 18: ...all the switch on the fuselage side opposite the muffler to prevent fuel from getting into the switch 15 Wrap the battery and receiver in 1 4 6 4mm thick foam rubber Place them into the fuselage as shown 16 Locate one of the discarded servo arms you cut off earlier You are going to use it as a strain relief for your receiver antenna Route the antenna through the arm as shown 17 Drill a 1 16 1 6mm ...

Page 19: ...n the chart that follows If your radio does not have dual rates we recommend setting the throws at the low rate setting Note The throws are measured at the widest part of the elevators rudder and ailerons BALANCE THE MODEL C G More than any other factor the C G balance point can have the greatest effect on how a model flies and may determine whether or not your first flight will be successful If y...

Page 20: ... engine propeller shaft and the bottom of the fuse under the TE of the fin Do this several times 2 If one wing always drops when you lift the model it means that side is heavy Balance the airplane by adding weight to the other wing tip An airplane that has been laterally balanced will track better in loops and other maneuvers IDENTIFY YOUR MODEL No matter if you fly at an AMA sanctioned R C club s...

Page 21: ...previous crash Keep all engine fuel in a safe place away from high heat sparks or flames as fuel is very flammable Do not smoke near the engine or fuel and remember that engine exhaust gives off a great deal of deadly carbon monoxide Therefore do not run the engine in a closed room or garage Get help from an experienced pilot when learning to operate engines Use safety glasses when starting or run...

Page 22: ...f applicable screw lock pushrod connectors etc 7 Add a drop of oil to the axles so the wheels will turn freely 8 Make sure all hinges are securely glued in place 9 Reinforce holes for wood screws with thin CA where appropriate servo mounting screws cowl mounting screws etc 10 Confirm that all controls operate in the correct direction and the throws are set up according to the manual 11 Make sure t...

Page 23: ... wind keeping the nose down to maintain airspeed and control Level the attitude when the model reaches the runway threshold modulating the throttle as necessary to maintain your glide path and airspeed If you are going to overshoot smoothly advance the throttle always ready on the right rudder to counteract torque and climb out to make another attempt When you re ready to make your landing flare a...

Page 24: ..._______ Where Purchased ____________________________ Date Construction Started _____________________ Date Construction Finished ____________________ Finished Weight ______________________________ Date of First Flight ____________________________ FLIGHT LOG ...

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