Zipp J.A.E. Racing JAE21G2 Building Instructions Download | Manualshive

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Tools and supplies needed to build

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Sanding blocks with 80 and 150 grit paper

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Drill with bits

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Square

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Flat file

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FLAT Workbench

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1/2 ounce Medium CA glue and accelerator

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Good quality 5 and 30 minute epoxy

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Epoxy finishing resin

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Spring clamps, paper clamps, c clamps, etc.

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Razor blade or X-Acto knife

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Masking tape

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Waxed paper

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Wood filler

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Primer

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Paint

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Summary of Contents for J.A.E. Racing JAE21G2

Page 1: ...C T U R I N G Kently Porter after smashing several IMPBA records with his JAE 21 JAE21G2 A Zippkits R C Boat Building Instructions 2009 Zipp Manufacturing Frankfort New York 13340 www zippkits com To...

Page 2: ...kit as the manual shows It is a good design handles excellent even at 84 mph and has no bad habits Don t try to second guess the designers This hull is the absolute pinnacle of model hydro design The...

Page 3: ...so 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 sharp Take the time to read this entir...

Page 4: ...t 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...

Page 5: ...to fit engine Tuned pipe 2 channel surface radio with 2 servos Throttle and rudder pushrods 2 56 Size with Clevises Zipp 2 pushrod seals Zipp 3404 8 ounce Fuel Tank Sullivan SS 8 Zipp 3473 187 strut Z...

Page 6: ...6 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 7: ...7 Miscellaneous parts...

Page 8: ...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 y...

Page 9: ...t 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...

Page 10: ...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 h...

Page 11: ...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 t...

Page 12: ...ugh 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 an...

Page 13: ...e 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 b...

Page 14: ...port 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 p...

Page 15: ...at the engine rails are not square 3 4x5 8 Be sure to lay them on the side they are 5 8 high Allow to cure Fit and glue the balsa tri stock inside the tub bottom Cut the balsa tri stock as follows 2 1...

Page 16: ...ube is a piece of cake if you know the secret The inch brass tubing needs to be annealed This will make it easy to bend by hand without kinks To anneal the tube simply heat it with any propane torch u...

Page 17: ...unt that you measured minus about 3 8 inch Mark the shaft tube here for reference Now study the side view of the shaft tube and carefully and slowly bend the S shape into the tube Try to make sure tha...

Page 18: ...h the shaft tube Strut in place on ski 12G kit shown 21 the same 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...

Page 19: ...semble the 4 parts of the ski using epoxy or CA Glue the aft ski bottom onto the sides Match the bottom sheeting to the front end of the sides and let the rear overhang Clamp or tape this assembly unt...

Page 20: ...This is done exactly like the tub bottom sheeting Sand a sharp bevel on the front of the ski bottom sheet so that it blends into the tub bottom Do not glue the ski to the tub yet Servos Bolt the rudde...

Page 21: ...ervo length Drill a inch hole inboard of your mark Assemble the rudder servo tray This is made from the servo mount base strap and the two 3 4x1 inch plywood blocks Check the length of your servo and...

Page 22: ...o that the rudder servo is about a half inch from the transom Install your solder clevis or Z bend attach the pushrod to the mounted servo and put the pushrod through the hole you made We like to use...

Page 23: ...scrap 5 16 from tub Throttle servo rails ready to glue to tub Don t get any glue on the servo or wire Allow to cure Assemble the throttle servo mounts using the scrap 5 16 balsa tri stock and the two...

Page 24: ...for the engine you are using and that the servo is not touching the tub floor 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...

Page 25: ...top Set these on waxed paper while they cure Use a metal acid brush bent near the bristle end to seal the upper part of the inside of the tub Allow to cure overnight Sand the top of the tub so that t...

Page 26: ...match tub Round off Once the top sheeting has cured sand the front of the tub flat and square Glue the pine tub nose block to the front of the tub Shape the block to match the tub Finish the nose bloc...

Page 27: ...ly sanding the edges Mix up some 30 minute epoxy and coat the inside of the sponson plates Also put some epoxy on the brass boom tube sleeves Shove the tubes in until they stick out the other side We...

Page 28: ...king out Glue the tubes and plates as before and weight or clamp until cured Be sure of this as this is one of those critical points When the sponson sides are cured let s do the sheeting This is wher...

Page 29: ...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 sponson step Use masking tape to hold it in place while it cures It s okay t...

Page 30: ...f 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 it much easier to sand them off...

Page 31: ...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...

Page 32: ...er propeller depth See drawing below and trim the front of the strut if needed Test fit the ski to the tub The rear of the ski should line up with the rear of the transom and the front should blend in...

Page 33: ...n fin with the supplied sheet metal screws and washers If you have a bottom overhang on the sponson sand it flush where the fin contacts it Note that you can later fine tune the fin with the oversized...

Page 34: ...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 sand with 600 800 and paint Use fuel proof paint or fuel proof clear...

Page 35: ...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 drive dog back on the shaft aligning the set screw in the flat you made Push the f...

Page 36: ...hrods 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 tank and mount with Velcro as well Mount the ru...

Page 37: ...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 Running It s better to start with a...

Page 38: ...38 Balsa tri stock cutting guide From the 4 pieces of tri stock cut as shown...

Page 39: ...tional Waters Website www intlwaters com Excellent forum for information on nitro powered boats NovaRossi US www novarossi us Source for the extremely fast NovaRossi 12 and 21 If you have a need for s...

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