Zipp Manufacturing Illusion Building Instructions Download Page 38 | Manualshive

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I L L U S I O N

36

Pushrod brace detail.

These braces are made to mount against the first
bulkhead, and support a ¼ inch pushrod.

Fuel Tank

We like using an IV bag (500mL) for a gas bag.

Very simple to use, water proof and rugged.

You can use any type of tank you want, just make sure that
you use gasoline compatible components…

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Summary of Contents for Illusion

Page 1: ...Z I P P M A N U FA C T U R I N G A Zippkits R C Boat Building Instructions 2009 Zipp Manufacturing 750 Ball Road Frankfort New York 13340 www zippkits com Toll Free 866 922 ZIPP...

Page 2: ...ttom Sheeting 13 Transom Assembly 16 Sealing interior 18 Deck Sheeting 19 Cowling 22 Cowl Mounting 25 S E C T I O N 3 E Q U I P M E N T Radio Box 14 Servo Installation 29 Engine Mounting 32 Setup Boar...

Page 3: ...ren without close adult supervision Here are a few safety tips Never operate your boat alone If you get hurt you may not be able to drive for help Never ever operate your boat in an area where there a...

Page 4: ...e boat is currently legal in all Gas Tunnel classes The Illusion was designed specifically for the Lawless G Drive and a Zenoah Gasoline engine It has not been tested with any other drives or engines...

Page 5: ...paper Drill with bits Square 12x48 FLAT plywood or bench the thicker the better Thin and Medium CA glue and accelerator Good quality 30 minute epoxy Epoxy finishing resin or West Systems Epoxy Screws...

Page 6: ...ible Zipp 470 prop starting point Cable grease Aeromarine 7145 2 feet large silicone tubing water line Before we can start building we need to do some prep work Good prep work will pay off later with...

Page 7: ...t to the bench Right and left are always as you are sitting in the boat or from the rear Got it If not stand on your head as you build Let s identify the parts in the sheets Don t remove the parts unt...

Page 8: ...I L L U S I O N 6 Take the time to mark all the parts as there are a few parts that are similar but not the same...

Page 9: ...I L L U S I O N 7 We like the Great Planes 11 inch bar sanders Use good quality epoxy and finishing resin Your life will be much easier with one of these Acid brush trimmed for fast epoxy application...

Page 10: ...a square to be sure that all bulkheads are 90 degrees to the side Remove all remaining bulkheads from their sheets and sand the edges smooth as before Make sure all parts are marked before you remove...

Page 11: ...slip them up into the bulkheads from the bottom You will have to lay them into position and rock them into place The fuselage sides start at the transom and go to bulkhead 7 Do not glue in place yet L...

Page 12: ...with 30 minute epoxy Glue the transom to the framework at this time as well Coat the tops of the mounts with epoxy as this area will be difficult to seal once the tunnel top is in place Tunnel Top Onc...

Page 13: ...her side Bottom Chines Remove the bottom chines from the sheets and sand lightly Press the bottom chine into the slits in the bulkheads Fit the tab into the slot at the nose of the side chine The fit...

Page 14: ...or so What we are trying to do with the plane is to shave the side chine to match the angle of the bulkheads When you have it close use your sanding block with 80 grit paper to finish Dry clamp the si...

Page 15: ...low to cure at least 3 hours Repeat on other side Bottom Sheeting When the side sheeting is fully cured plane and sand the side sheeting even with the bottom of the bulkheads Be careful not to change...

Page 16: ...a piece of plastic wrap or waxed paper on your bench Using CA glue the two small sides to the two long sides The small sides go between the long ones Use a square Put glue on the edges and join the tw...

Page 17: ...long the line you drew Glue the radio box tongue to the spacer with medium CA Try not to get any glue under the lip as it will interfere with the mounting of the radio box The back of the tongue shoul...

Page 18: ...block With your razor saw cut all the tabs that are holding your hull to the building jig Ditch the jig We don t need it any more Hey this is really starting to look like something now After you finis...

Page 19: ...nstall the side extensions with medium CA Do not use accelerator Repeat on other side When the transom assembly is cured install the transom braces with medium CA Do not use accelerator and glue in on...

Page 20: ...ed and see the side pop off the boat because you thinned the sealer too much Don t ask Start from the front Using a brush coat all areas of wood inside the hull Get inside the holes Continue coating t...

Page 21: ...thin it Using a credit card or similar squeegee some epoxy on the bottom side of the deck Do the entire surface This will waterproof the underside of the deck Get it pretty thin The resin goes a long...

Page 22: ...e as well Allow to cure overnight After the deck sheeting is fully cured use your plane and 80 grit to sand flush Give the whole boat a good sanding with your 80 grit block Use wood filler to fill any...

Page 23: ...nice round shape At this time you should look over the entire hull and sand any glue bumps or uneven seams etc Center Section Nose Blocks These are the two shaped balsa blocks They fair the front of t...

Page 24: ...h the top and a little short on the bottom Use medium CA Sand the tops flush with the center section top and sand the tunnel top sheeting to meet them Cowling The cowling is pretty simple It s importa...

Page 25: ...he cowl bottom so that it has a bevel This is needed to allow the bottom to fit inside the very nose of the cowling Sand the inside of the cowling where the bottom will be Also true up the bottom of t...

Page 26: ...tom and make sure it is flush with the bottom edge of the cowling Set this aside in the upright position so that a glue fillet will naturally form Once the cowl bottom is fully cured it s time to cut...

Page 27: ...cowling on the edge of your bench You can also use a razor saw or Dremel Now we can trim the inside of the nose blocks for clearance Use your razor saw to trim the insides of the balsa nose blocks so...

Page 28: ...ng on the top deck Push the cowling into the bulkhead so that it transfers the ink to the bulkhead Remove the cowl and carefully center punch your mark and drill a inch hole Slide the cowling back on...

Page 29: ...ear of cowling marked for trimming Cowling trimmed With the cowling fully seated mark and trim off the excess in the rear Sand the edge so that it is even Make a mark 2 inches forward of the rear of t...

Page 30: ...n to clean the threads Bolt the cowling on with the supplied 20 nylon bolts Next we will mount everything we need to make this boat go Radio Find the 2 pieces of x1 1 2 ply and the 6 pieces of tri sto...

Page 31: ...ervo to the mounts making sure the case does not touch the mount Lay the mounted servo on the bench Check to see that it sits flat on the bench If not find out why and correct it If you are using two...

Page 32: ...of the mount to your line You can use medium CA for this Extend your line 2 11 16 from the edge of the first mount and glue in the other mount Make sure it is level and parallel with the first mount C...

Page 33: ...g trim is centered Put the servo arms on the servos and center them on the rails Mark the holes and drill for the servo screws Once all the servos are fitted remove everything from the box Go over all...

Page 34: ...er onto some waxed paper and seal the bottom Allow to cure overnight While you have epoxy mixed seal the radio box lid the same way Do both sides as well as the edges and lay it on waxed paper to cure...

Page 35: ...tached to transom Holes center punched Engine mount bolted to transom Align the top of the pattern with the top of the transom and center it side to side Use a punch to mark the holes Remove the patte...

Page 36: ...e put the nut plate outside the transom and used shorter bolts It is much easier to adjust from inside the transom At this time you should make a setup board from a piece of flat ply or 1x stock Make...

Page 37: ...hers in the rear If you have trouble sliding the front mount in place you can use a file to clean the slot Pushrods The throttle and steering pushrods are entirely up to you We used some fiberglass tu...

Page 38: ...de to mount against the first bulkhead and support a inch pushrod Fuel Tank We like using an IV bag 500mL for a gas bag Very simple to use water proof and rugged You can use any type of tank you want...

Page 39: ...t have to be sanded off later This first coat is easy as the wood will darken as it gets wetted with resin The second coat will be a little more challenging but will use far less resin and be faster t...

Page 40: ...um coat of primer When dry wet sand with 600 or 800 Use compressed air or a vacuum to remove the dust on the inside and outside of the hull Wipe down the entire boat with alcohol Use a tack cloth to l...

Page 41: ...the engine to the rudder pushrods Is the engine straight If not adjust the ball links until it is Be sure to put the screws in the servo arms Adjust the throttle so that the carb is wide open when you...

Page 42: ...irst and only add weight if you can t trim the boat otherwise Running Under no circumstances should you ever run a marine engine for an extended time without cooling water At the pond Make sure your t...

Page 43: ...gine warm up for 30 seconds or so before giving it full throttle Drive past yourself and make sure you have a stream of cooling water If you don t see any bring it in pronto If all looks good hit it N...

Page 44: ...om This is the pivot point for turning A forward CG keeps the hull wetter preventing blowovers Limits absolute top speed due to drag An aft CG keeps the hull out of the water and usually blows over wi...

Page 45: ...ve angle positive Boat plows CG too far forward Drive angle too negative Debris caught under boat Boat is very light and unstable Drive too deep Drive positive Boat needs left trim to go straight Prop...

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