Zipp Manufacturing JAE12G2 Building Instructions Download Page 4

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Additional items needed to complete

.12-.20 air or water cooled Nitro engine

.150 Collet and flywheel for engine

Starting belt

.150x16 inch cable w/welded 3/16 stub shaft (Zipp 3475)

Header to fit engine

Tuned pipe

2 channel surface radio with 2 servos (Hitec HS-225MG and HS-85 recommended)

Throttle and rudder pushrods (2-56 Size) (Zipp 3462)

2-56 Clevises (Zipp 3459)

2 pushrod seals (Zipp 3404)

4 ounce Fuel Tank (Sullivan SS-4)

Z21 Strut (Zipp 3495)

.187 drive dog (Zipp 3485)

440 prop (Zipp 4007)

10-32 Prop nuts (Zipp 3489)

Engine Mounts (Solinger 12 recommended, Zipp 3481)

Cable grease

Rudder (Zipp 3477)

12 inch length of 1/4 brass tubing (Zipp 3474)

Summary of Contents for JAE12G2

Page 1: ...1 Z I P P M A N U FA C T U R I N G JAE12G2 A Zippkits R C Boat Building Instructions 2009 Zipp Manufacturing Frankfort New York 13340 www zippkits com Toll Free 866 922 ZIPP ...

Page 2: ...t overhangs This boat is designed to shear water and prevent any capillary action of water To do this the tub ski and sponsons have rear overhangs These shear the water off and must be left in place and not rounded in any way The boat also has side overhangs on the sponsons These help the boat get up on plane quicker If you are using a powerful engine you can sand these off but leave all corners s...

Page 3: ...it paper Drill with bits Square Flat file FLAT Workbench 1 2 ounce Medium CA glue and accelerator Good quality 5 and 30 minute epoxy Epoxy finishing resin Spring clamps paper clamps c clamps etc Razor blade or X Acto knife Masking tape Waxed paper Wood filler Primer Paint ...

Page 4: ...channel surface radio with 2 servos Hitec HS 225MG and HS 85 recommended Throttle and rudder pushrods 2 56 Size Zipp 3462 2 56 Clevises Zipp 3459 2 pushrod seals Zipp 3404 4 ounce Fuel Tank Sullivan SS 4 Z21 Strut Zipp 3495 187 drive dog Zipp 3485 440 prop Zipp 4007 10 32 Prop nuts Zipp 3489 Engine Mounts Solinger 12 recommended Zipp 3481 Cable grease Rudder Zipp 3477 12 inch length of 1 4 brass t...

Page 5: ...5 Let s identify the parts so that we can easily find them when needed Mark the parts that are inside other parts 1 16 plywood parts 1 8 plywood parts ...

Page 6: ...6 Miscellaneous parts Foam parts Left sponson has 2 holes Right sponson has 6 holes Foam nose block ...

Page 7: ...ig We recommend that you make a jig for the tub This can be as simple as two straight pieces of to inch thick wood It can be as elaborate as 1 8 by 2 inch aluminum angle with adjustment slots for different tub widths Either way you need something to clamp the tub sides to Every critical component on this hull depends on a straight square tub Do whatever it takes to get it done correctly ...

Page 8: ...it won t be seen later Check the fit of the bulkheads in the right tub side Use a file to touch up the inside corners on the bulkheads to square off the tiny radius left by the cutting bit Once you are happy with the fit of the bulkheads in the tub side glue them in with CA Use the square provided in the kit to ensure each bulkhead is perfectly square Make a mark on both tub sides inside with a li...

Page 9: ...he left tub side If all is well glue the bulkheads in place one at a time using the square from the kit Flip the tub over and lightly sand the bottom Now is the time to use your tub jig If you don t have the ability to make an aluminum jig see below Use a pair of thick wooden sticks Leave these clamped to the sides while gluing the aft bottom in place ...

Page 10: ... the tub nose block Using epoxy glue the tub aft bottom in place Make sure that the bottom extends to the front bulkhead It should cover the full 1 8 inch bulkhead Later on we will sand this to match the angle of the tub sides Leave a small overhang at the rear of the tub Do not sand this off The aft bottom sheet is pre cut to the correct length Make the front of this flush with the front of the f...

Page 11: ...ough the last inch or so of each end Put the rear tube doublers in place and slip a boom tube sleeve and carbon boom tube through the tub and doublers Measure the carbon tube on each side of the tub and center it Make some pencil marks on the tube on the outsides of the tub so that you can quickly center the tube later Do the same for the forward boom tube and doublers The forward boom tube double...

Page 12: ...ee that the tubes are square front to back with the boom square provided in the kit When you have checked and double checked that the boom tubes are straight and square to the world remove the clamps but leave everything in place Mix up some 30 minute epoxy and coat the doublers where they will be in contact with the tub sides and bottom Align the rails and clamp in place Quickly check your measur...

Page 13: ...pport This gets attached to the rear of bulkhead 2 and is flush with the lower portion of the sides Check the fit of the foam nose block If all is well glue the foam nose block in place with epoxy or poly glue Allow to cure Sand the foam flush with the tub sides Be careful not to sand the tub sides too much This foam is needed for floatation in case you shear off both sponsons ...

Page 14: ... Using epoxy glue the two maple engine rails in place touching the aft boom tube doubler Allow to cure Fit and glue the balsa tri stock inside the tub bottom Cut the balsa tri stock as follows 2 10 inches 4 9 inches 2 5 inches 2 4 1 4 Cut the longest pieces first See cutting guide in back of this manual These are slightly long Trim for an exact fit in the radio box and engine area Use the piece of...

Page 15: ...ed with the mounts Drill pilot holes to avoid splitting the engine rails If using the Solinger mounts drill 3 32 pilot holes With the engine in place we can move on to the shaft tube This is another area that will need to be done perfectly for a good running hull Bending the shaft tube is a piece of cake if you know the secret The inch brass tubing needs to be annealed This will make it easy to be...

Page 16: ...ex cable better reducing cable whip and drag Measure from the end of the engine collet to the rear bulkhead Remove the engine Put the shaft tube through the hole in the rear bulkhead and the hole in the tub bottom Put the end that you didn t anneal towards the engine Let the tube stick through the rear bulkhead by the same amount that you measured minus about 3 8 inch Mark the shaft tube here for ...

Page 17: ...u should have a nice S tube that starts about 3 8 inch behind the engine collet and continues past the rear of the boat we will trim it later Glue the shaft tube in place with epoxy and filler to thicken Be sure to get inside and outside the tub and both sides of the bulkhead Allow to cure ...

Page 18: ...m Ski Assemble the 3 parts of the ski using epoxy or CA Glue the ski bottom onto the sides Match the bottom sheeting to the rear end of the sides and let the front overhang Clamp or tape this assembly until cured Sand the front of the sheeting so that it feathers to nothing at the front ...

Page 19: ... blends into the tub bottom Do not glue the ski to the tub yet Servos Bolt the rudder in place This should be as far to the right as possible and be sure that you have at least inch of rudder below the bottom of the ski Make a mark on the transom where the rudder pushrod will exit Sight this from behind the boat see drawing Drill a inch hole inboard of your mark ...

Page 20: ...x8 inch plywood blocks Check the length of your servo and glue the blocks in place This tray will fit the Hitec HS 225MG servo Use epoxy or medium CA to build the tray Check the fit of the servo in the tray You will have to cut a recess for the servo wire in one block Make sure that the servo is a tiny bit taller that the mount otherwise the strap won t tighten the servo Use two servo screws not s...

Page 21: ...through the hole you made We like to use a steel clevis or Z bend on the servo end and a threaded clevis on the rudder end This allows you to adjust the pushrod length from outside the radio box Screw on the rudder clevis so that about 1 8 inch is inside the clevis for adjustment and attach it to the rudder control arm Make sure that the servo arm is straight up Glue the servo tray to the tub floo...

Page 22: ...ing two servo screws Be sure to drill pilot holes so that the mount doesn t split Glue these to the tub Be sure that the servo is on the correct side for the engine you are using We like to use a nylon clevis on the throttle end and an EZ connector on the servo end of the throttle You may need to use a small set screw instead of the screw that comes with the EZ connector to make it fit under the l...

Page 23: ...e tub sides Try to get them flush or slightly above the sides Use epoxy finishing resin or West Systems epoxy to seal the inside of the tub Be sure to seal around the boom tube sleeves pushrod holes and all around the servo mounts Use any excess epoxy to seal the ski inside and out as well as one side of the radio box top Set these on waxed paper while they cure Use a metal acid brush bent near th...

Page 24: ... the lower portion of the aft end of the tub sitting on the lid frame support glued to the back of bulkhead 2 Allow to cure Sand the frame and glue the tub top sheeting in place with 30 minute epoxy Make sure that the sheeting is flush with the transom and is centered Look at the lip all around the radio box and make sure that it is centered as well Tape and weight until cured Once the top sheetin...

Page 25: ... way it can be done right Gather all of the parts for the right sponson The right sponson holds the turn fin so it has dowels in it Grab the right foam sponson Test fit the 3 8 inch wood dowels in the 4 rear holes Also test fit the 2 brass tubes They should be a nice fit without slop Prepare the sponson inside and outside plates by lightly sanding the edges Mix up some 30 minute epoxy and coat the...

Page 26: ...es and dowels go through both sponson plates The tubes and dowels should protrude through and be flush with the outside plate Use tape and small weights to hold the sponson and allow to cure on waxed paper While the right sponson is curing you can glue the left sponson Everything is the same except the left sponson has only the two tubes Make sure that the left sponson is a mirror image of the rig...

Page 27: ...ng and you won t have any trouble If something doesn t seem to fit stop and find out why Epoxy is impossible to remove from foam Grab all the sheeting pieces including the ones you marked earlier Use a file to sharpen the inside corner of the sponson step as shown Use your sanding block with 80 grit paper to sand the foam flush with both sponson plates Using epoxy glue R 1 in place on the ...

Page 28: ...eaving equal overhang on both sides and an overhang on the rear Glue R 4 with equal overhang on the sides and leave an overhang in the rear Note that the bottom overhangs don t get sanded off if you plan to use a low power engine If you are using a high performance engine glue the bottom sheets so that all of the overhang is on the outside of the sponson opposite the sponson tubes This will make i...

Page 29: ...e rear of this square just like the tub bottom Sand the top of R 2 and glue the sponson top on R 6 When cured sand the front until it is flat and square Glue the pine sponson tip in place with epoxy When cured sand the nose block to a nice blunt tip Also sand the top sheeting R 2 and the tips flush with the sides Do not sand off the overhang on the sponson bottom unless you are using a high power ...

Page 30: ...t on the other sponson Strut Mount your strut to the transom using center marks to align it Make it so that when the strut is in the middle of its travel the bottom of the strut is about 1 2 inch below the tub bottom You may have to adjust the shaft tube some more The strut needs to be at the very bottom of the ski for the proper propeller depth See drawing below and trim the front of the strut if...

Page 31: ...ing 30 minute epoxy seal the bottom of the tub in the area of the ski and epoxy the ski in place Be sure that the inside of the ski is sealed with epoxy Tape and weight the ski check alignment and allow to cure Turn Fin Sharpen the outside of the turn fin Mark the center of the turn fin dowels Drill 3 32 pilot holes on your marks Attach the turn fin with the supplied sheet metal screws and washers...

Page 32: ... the other side of the radio box top When cured sand with 150 and recoat with epoxy This coat will use far less resin than the first When this cures wet sand the bottom of everything with 220 If you are painting sand the entire boat with 220 Now is the time for primer Wet sand the primer with 400 and use spot putty to fill any imperfections Wet sand with 400 and lay on a heavy coat of primer Wet s...

Page 33: ... needs to be at the very bottom of the ski for the proper propeller depth Slide your drive dog onto your flex shaft then your prop Leave about half of the threads showing past the prop Tighten the drive dog set screw Remove the prop and measure the exact location of the set screw from the end of the shaft Remove the drive dog and file or grind a flat spot on the shaft about 1 8 inch wide Put the d...

Page 34: ...g trim is in the center Move the steering servo arm so that it is straight up Put the servo arm screw in Mount the throttle servo arm so that it is at about 2 o clock with the trigger at neutral Put the servo arm screw in Install the servos and pushrods again only this time glue pushrod seals in place with Goop Mount your receiver and battery pack with double sided tape or Velcro Assemble the fuel...

Page 35: ...ur switch through the lid with a waterproof switch cover Make sure that your tuned pipe is mounted to the tub Make sure your prop is sharpened and balanced Grease the flex shaft with cable grease or high quality marine grease Put your starting belt in place and then install the flex cable Hook up your fuel and pressure lines Center Of Gravity This hull has a wide range as far as the CG is concerne...

Page 36: ...o lean it will simply quit No fun with a boat Start rich The main thing is to get the boat running smoothly and turning well After that try different props pipe lengths and needle settings For a bunch of help tuning and running go to some of the R C boating web sites One of the most popular is International Waters www intlwaters com Good luck and happy boating Balsa tri stock cutting guide ...

Page 37: ...37 From the 4 pieces of tri stock cut as shown Also cut the 5 16 tri stock as shown Additional information ...

Page 38: ...powered boats Solinger R C www solingerrc com Custom parts for the JAE CNC mounts rudder etc All designed for the JAE Note that Zippkits is a Solinger Dealer NovaRossi US www novarossi us Source for the extremely fast NovaRossi 12 and 21 If you have a need for speed this is the engine you need ...

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