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The Toughest R/C  Planes Ever!

5376 Amalfi Drive,

Clay, NY  13041

www.tufflight.com

Items Included in kit:

Foam Parts:

(1) right/left EPP wing cores in shucks
(2) EPP tail feathers sheets in shucks with wings
(1) EPP front fuselage piece
(1) EPP rear fuselage piece

Misc:

(2) 0.038” control horn clear plastic sheet
(1) 0.005” 1” x 8” clear mylar rudder hinge
(1) 0.003” 3” clear mylar hinge material
(1) 1/32” x 1/2” G10 strip
(1) 1/32” x 12” G10 sheet
(1) 1/16” G10 sheet
(1) 3/8” white plastic motor mount sheet
(2) 1/16” x 3/4” fiberglass LG struts
(6) 1/16” x 72” fiberglass rod
(1) 0.188” x 18.5" carbon tube
(2) 1/4” x 3.75” fiberglass rod
(2) 1/8” x 1-3/8” fiberglass rod

Hardware:

(4) Dubro mini EZ connectors
(3) Dubro 2-56 x 12” threaded rod
(3) Dubro 2-56 nylon clevis
(2) main wheels
(1) tailwheel
(8) 4-40 x 5/16” nylon bolts
(2) 6-32 x 3/8” nylon bolts
(2) 6-32 x 1-1/4” steel bolts
(6) 6-32 nuts
(1) 0.039” x 18” wire
(1) 1/16” x 7” wire
(2) zip ties
(8) O-rings #017
(2) Velcro strap
(4) #64 rubber bands

Template / Plans Packet
This Instruction Manual

Rev 1.0

Hello, and thanks for buying the Big Bouncer!  Whether you’ve just entered the exciting world of radio control and

3D flying, or you’re a seasoned veteran, the Bouncer  is the perfect combination of agility, durability, versatility and value
for the schoolyard, park or front yard 3D flyer.

Caution:

 The Bouncer can be a very agile performer, and requires care in setup and operation.  Please obey

manufacturer’s safety rules for your motor, propeller and battery.  Lithium polymer (lipo) batteries are ideal for
this plane.  

Charge lipo batteries ONLY with a lithium capable charger according to battery instructions.

The CG location is 6-3/4” from the wing leading edge at the root.

While you may be tempted to fly close to yourself, please practice in a safe manner.

Please read and understand the instructions before starting to build.  We recommend joining the AMA and

following the AMA safety code.  Call 1 (800) I- FLY-AMA for more details.

We assume no responsibility for how you use your plane.  That said, let's get started!

Excellent 

3D

 capability -plus- Outstanding 

Durability

Wingspan:

55"

Length:

58"

Wing Area:

831 sq in

Flying Weight:

 

4.5 lbs

BIG Bouncer

Motor:

 ~800 W

Radio:

4 channels

Servos:

4  HS 65 or equivalent aileron
2 HS 85 or equivalent elevator
1 HS 225 or equivalent rudder

Summary of Contents for Big Bouncer

Page 1: ...Bouncer Whether you ve just entered the exciting world of radio control and 3D flying or you re a seasoned veteran the Bouncer is the perfect combination of agility durability versatility and value fo...

Page 2: ...ate and velcro strap on the fuselage for the new battery position AgoodtestforanaerobaticCGpositionistoflythe plane upright and trim the elevator for level flight Then flyinvertedandseeifanydownelevat...

Page 3: ...Step 8 Align aileron to wing as shown Step9 TrimAileron to match wing tip angle with sharp hobby knife as shown Step 10 Make slicing tool from scrap wood and razor blade exactly 0 470 thick Assemble...

Page 4: ...l parts to the bench when slicing Step 17 Trim hinge at angle as shown to aid insertion during next step Step 16 Apply kicker to hinge Step 15 Apply thin CAto hinge on both sides Step 20 Once hinge ga...

Page 5: ...24 pieces Work glue into the entire slot from nose to tail Cut the 48 pieces first You ll use the 24 pieces now Save the other ones for the wing later There are 8 line marks for you to slice Use your...

Page 6: ...location on fuselage as shown Step 33 Measure and mark the center location for the wing rear position Step 34 Connect the spar location marks as shown Step 36 Poke and slice carefully through to the...

Page 7: ...uick gripintowingslots Work quickly for this and the following steps one wing at a time Step 50 Repeat for bottom side joints as shown Step 41 Obtain two identical large blocks to use as supports duri...

Page 8: ...r Mount You ll need scissors white motor mount plastic paper templates 3M77 drill motor Step 58 Saw to remove H insides as shown Step 57 Drill 1 4 holes where indicated at H corners Step 56 Drill cent...

Page 9: ...ip ruler cutting board mylar hinge material clamps rear fuselage strong scissors tin snips Note wires route on left side of fuselage Step 70 Make slices for mylar hinges as indicated Step 67 Glue the...

Page 10: ...a point as shown not critical Step 76 Glue the spar into the horizontal stab as shown Step 77 Tape the joint to clamp it while the glue dries Step 78 Carefully remove the tape when glue is dry Step 7...

Page 11: ...ep 86 Select the bottom surface and measure location for elevator horns Step 87 Slice the foam as shown for the horns cut all the way to the top surface Step 88 Glue horns in place as shown Horns shou...

Page 12: ...ure to flex the hinge for your desired travel 50 degrees each way is good for 3D Step 96 Gather parts and tools Make and Apply Fuse Reinforcements You ll need scissors thick and thin G10 material pape...

Page 13: ...hown with white gorilla glue or quick grip Use plenty of glue for G10 to foam joint Step 107 Glue G10 reinforcements to other side as shown Step 106 Repeat for bottom rod Step 108 Align rods so they g...

Page 14: ...t Step 111 Apply glue to joiner doublers spacers as shown Step 112 Glue joiner doubler spacers together as shown Step 114 Assemble joiners as shown Step 116 Glue assembled joiners to fuse lage as show...

Page 15: ...ns so their wires will reach the receiver 1 1 2 from hinge locate tip aileron servos about 19 from wing root Step 127 Test fit servo and make slits in foam for wire to RX as shown Step 126 Slice servo...

Page 16: ...xtensions to reach the RX Step 135 Cut a channel down the bottom center for the wires Step 136 Feed the wires through channels Step 137 Tuck the wires into channel and tape in place as shown Step 140...

Page 17: ...ice as needed Step 145 Install rudder control horn as you did the others Elevator and rudder use 2 56 rods and clevises Clevises go into control horn end z bends give better clearance at servo end Ste...

Page 18: ...rt carbon tube to locate support inserts as shown Step 158 Glue support inserts to one support plate with CA and kicker as shown Repeat Steps for other LG Strut also Drill holes first Heavy duty tin s...

Page 19: ...s step The edge marks location of LG spar to be inserted into wing and through fuselage Step 167 With a sharp hobby knife slice the borders for the LG supports as shown Step 168 Using Dremel tool with...

Page 20: ...ube as shown Step 175 Test fit gear supports and tube Clear any foam which prevents full insertion Step 179 Check and adjust alignment as needed while glue cures Step 180 Attach 64 rubber bands as sho...

Page 21: ...0 supports and clamp till dry Step 184 Slice the rudder as shown to receive wire Slice should be next to hinge for best strength Refer to template for G10 reinforcement location Step 186 Gather parts...

Page 22: ...ugh fuse to poke zip tie around G10 reinforcements as shown Step 196 Mount secured as shown Re peat for all 4 corners of H mount Step 195 Stretch behind H mount and around rod as shown Step 194 Apply...

Page 23: ...ttery Step 206 Slice through fuselage above and below battery edge locations as shown Step 205 Mark center of battery as shown Step 204 Make hole in wing to clear battery connector if needed Step 209...

Page 24: ...hard nose down crashes It can be installed at any time Step 216 Smear Quick Grip over any foam corners likely to contact the ground Step 215 Apply mylar strips to avoid scuffs when taxiing aggressive...

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