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-AMR 25% Super Decathlon-

Building manual

-96’’ wing span---64 ½’’ fuselage---1 488 Sq. In.---35/50cc engine-

www.amr-rc.com

October 24, 2012

Содержание 25% Super Decathlon

Страница 1: ... AMR 25 Super Decathlon Building manual 96 wing span 64 fuselage 1 488 Sq In 35 50cc engine www amr rc com October 24 2012 ...

Страница 2: ...nge or modify this warranty without notice Aircraft Modelers Research has no control over the final assembly or materials used for final assembly no liability shall be assumed nor accepted for any damage resulting from use by the user of the user assembled product By the act of using the user assembled product the user accepts all resulting liability Buyers must be prepared to accept all reasonabl...

Страница 3: ...e of your completed model and no representations are expressed or implied as to the performance or safety of your completed model Before starting to build use the Part List on the next pages to take an inventory of your kit to make sure it is complete and inspect the parts to make sure they are of acceptable quality Remember to take your time and follow the instructions to end up with a well built...

Страница 4: ...netrate deep into the wood fibbers creating a very strong bond We recommend these brands G2 Epoxy kit T88 Epoxy or West Systems They are available from any Aircraft or Marine specialty shops in convenient sizes Carefully follow their mixing ratios 3 We recommend that all control horns be 8 32 types no less and that all screws nuts be secured with thread locker 4 A straight airframe is the only way...

Страница 5: ...0 to 50CC engines are suitable for this plane It is strongly recommended to stay within this range Failure to follow this recommendation may damage the airplane since it is not design for larger engines The plane fly very well when properly balanced and trimmed First flight should be done by experienced pilot only even if it is easy to fly once trimmed ...

Страница 6: ...n nuts 52 7 8 x 24 Alu Wing tube socket 1 6 32 Nylon nuts 2 058 Flying wire 4 foot 4 40 Blind nuts 8 Sullivan steel tabs 8 6 32 Blind nuts 2 032 x 4 x 10 Alu sheet 1 8 32 Blind nuts 6 Glass wing tips 2 1 4 20 Blind nuts 2 Glass wheel pants 2 Sullivan Control Horns 4 Glass cowling 2 pieces Sullivan Control Horns rudder 1 Glass dashboard 1 Strut Bracket SD50BR5 2 Window set 1 Flying wire bracket SD5...

Страница 7: ... 11 1 4 x 1 4 x 36 Balsa sticks 8 1 4 x 3 8 x 48 Balsa sticks 1 3 8 x 3 8 x 36 Balsa sticks 8 3 8 x 1 2 x 24 Balsa sticks 1 1 2 x 1 x 48 Balsa sticks 2 1 4 x 1 2 x 48 Hardwood 8 3 8 x 3 8 x 48 Hardwood 1 1 2 x 48 Triangular Hardwood 1 3 4 x 3 4 x 6 Hardwood 1 Small struts Hardwood 2 Large struts Hardwood 2 3 8 x 6 Dowel 1 5 8 x 6 Dowel 1 ...

Страница 8: ...ing Wood After removing parts from the laser cut plywood and balsa it is highly recommended to keep some scrap pieces for later use during the build Tools Long sanding block X Acto cutter or razor blades modeling saw masking tape ruler square small plane to rough leading edge or other parts various power tools as available ALWAYS DRY FIT PARTS PRIOR APPLYING ANY GLUE ...

Страница 9: ...FUSELAGE ASSEMBLY Follow directions carefully Always dry fit first Assemble all components on a flat building board 9 ...

Страница 10: ... side since the fuselage is build from the bottom 2 Once fit is found correct apply glue to join both parts as shown Assembly will be done over FC1 assembly STEP2 10 1 Dry fit assembly of 2 F1A and 2 F1B and 1 F1C as shown 2 Once fit is found correct apply glue to join both parts 3 Use 2 X 5 8 wood screws as shown to secure F1C F1B F1A F1C F1B F1A 4 X 5 8 wood screws 10 ...

Страница 11: ...ick on both sides 1 Dry fit STEP2 assembly on F1 to make sure it fit properly 2 Once fit is found correct apply glue to join both parts as shown 3 Cut 2 1 2 triangular hardwood sticks 3 inches long and glue behind F1 as shown 11 ...

Страница 12: ... both parts as shown F3A 6 32 BLIND NUTS STEP5 1 Glue F23 over F22 and make sure to align holes properly Notice that F23 is wider than F22 2 Glue F24 over F23 and make sure to align holes properly Notice that F24 is the same width than F23 3 Install 6 8 32 blind nuts as shown on F24 Apply glue around blind nut flanges 8 32 BLIND NUTS F24 F23 F22 12 ...

Страница 13: ... Dry fit F31 to F2A and F3A Once fit is found correct apply glue to join both parts as shown F3 NOTICE 2 BLIND NUTS ROW NEAR F2 STEP7 13 1 Dry fit first Install STEP6 assy and F4 to F9 2 Glue all parts over FC1 Make sure that they are perpendicular to FC1 assy STEP6 assy F4 F5 F6 F7 F8 F9 ...

Страница 14: ...hown F10 STEP9 14 1 Glue 2 3 8 sq balsa 28in long on rear of fuselage 2 Fit and glue sq balsa as shown 1 4sq balsa sticks On both sides 3 8sq balsa sticks On both sides Trim 1 4sq balsa to fit 3 8 sq stick 1 8 Top view side view Do not sand the side of 3 8 balsa at this time FSR ...

Страница 15: ...STEP10 FB 1 Dry fit FB over assembly as shown 2 Glue FB as shown STEP11 15 1 Dry fit and glue STEP4 assembly F4A and F5A as shown STEP4 assembly F2A F3A and F31 F4A F5A ...

Страница 16: ...ks 2 Glue sticks as shown between F3A and F6 as shown Trim excess flush with F3A STEP13 16 1 Use F11 to mark line on 3 8sq balsa stick and remove material 1 8 deep as shown prior installing F11 and F11A Use F11 over 3 8 stick to mark line and remove material 1 8 deep F3A F6 ...

Страница 17: ...ust be inside STEP15A 17 1 Glue F11 over F11A 2 Drill 1 4 dia hole in 3 8 balsa at 1 inch from existing hole use tail wheel to locate the hole properly 3 Glue 1 4 dia dowel 3 4 inch long 4 Drill 5 64 2mm dia hole in the center of the dowel Glue 1 4 dia dowel And drill 5 64 dia hole in center F11A F11 Drill dia hole F11A 1 ...

Страница 18: ...STEP15B 1 Cut and glue 3 8sq sticks to brace rear of fuselage bottom as shown 18 2 Cut and glue 3 8sq balsa sticks to brace sides of rear fuselage as shown as shown ...

Страница 19: ...in front of building table 2 Dry fit first and glue F1 assembly step2 to fuselage assembly as shown 3 Cut 2 1 2 triangular hardwood sticks 5 inches long and glue them inside fuselage as shown on both sides 19 Glue 1 2 triangular hardwood both sides STEP2 assembly F1 ...

Страница 20: ...wood sticks and glue them in slot found in F13A as shown 3 Locate F13 over the hardwood block and drill 4 holes in hardwood stick using holes found in F13 4 Use 4 No2 1 2 long screws to secure F13 This plate is used for throttle and choke servo installation NOTE It is highly recommended to install these servos prior completing the sheeting 20 Hardwood sticks 3 8 X 1 2 F13A F13 ...

Страница 21: ...ane This servos installation is suggested but can vary depending on engine type and builder choice It is also recommended to use velcro tape under ignition to help to maintain it in place and to reduce vibration A plastic tie wrap is mandatory to secure ignition onto F13 not shown in picture below It is also better to make engine installation and adjust pushrods as required at this moment 21 IGNIT...

Страница 22: ... sticks between F1 and F2A as shown 2 Sand flush at both end 3 Sand to match F1 and F2A shape 22 F2B 3 8 balsa sticks STEP18 1 Glue 1 F2C and 1 F2E on both sides as shown 2 Glue F2B and F2D as shown F2D F2C PHOTO SABLAGE ICI F2C ...

Страница 23: ...STEP19 1 Glue F4B as shown 2 Glue 4 F4C on front and rear each sides of F4B 23 F9B F4B STEP20 1 Glue F5BB FF6B F7B F8B and F9B as shown F5B F4C X4 F6B F7B F8B ...

Страница 24: ...STEP21 1 Glue 2 F16 as shown 24 F16 STEP22 1 Glue F16A outside F16 as shown 2 Glue F17 as shown F17 F16A ...

Страница 25: ... hardwood sticks They should fit between both F16A 2 Glue 2 1 4 X 1 2 hardwood sticks as shown 25 x hardwood sticks STEP24 1 Glue F15 as shown on both sides F15R F16A F16A F15L F15L and F15R not flush with FSL and FSR F15L FSL ...

Страница 26: ... shown F14 should be flush with tabs on top of F5B 26 F14 STEP26 1 Glue 2 1 4sq balsa stick as shown They must locate on F15 2 Trim flush with F9B 1 4sq balsa sticks F14 F5B 1 4sq sticks F15 Fill with scrap balsa if required ...

Страница 27: ... F28 F29 and F30 both sides as shown 27 F30 STEP28 1 Cut 2 3 8 x 1 2 hardwood stick as shown 2 Glue rear stick flush with F14 slot top 3 Glue front stick in F30 slots 4 Glue 2 F35 on both sides as shown 1 4 X 1 2 hardwood stick 3 8 x1 2 sticks F14 Flush F35 F28 F29 ...

Страница 28: ...ndow thickness STEP30 1 Cut 2 1 8 sheeting and fit as required 2 Glue bottom sheeting as shown between F4B and F5B 3 Trim flush with F14 side and F15 inside face 4 Repeat procedure for top sheeting Front end should be flush with F18 cover 5 Top sheeting should be flush to F14 outside and with F16A inside F16 should not be covered by sheeting 6 Install F18 using No2 X screws 1 8 X 1 2 balsa strip F...

Страница 29: ...STEP31a 1 Cut 1 servo wiring tube 15 inches long 2 Glue the tube flush with F9B and apply glue in holes of F6B to F8B 29 Servo wiring tube Servo wiring tube Flush with F9B ...

Страница 30: ...lying wire bracket 1 Install 4 6 32 T nuts inside the fuselage 2 Install fuselage front brackets as shown using 4 6 32 SHCS 5 8 long and 4 6 washer as shown Use 2 6 32 locknuts inside the fuselage to secure screws as shown 3 Install tail flying wire bracket as shown using 2 4 40 SHCS 1 2 long and 2 4 as shown ...

Страница 31: ...FUSELAGE ASSY PICTURES 1 Add scrap balsa to support covering properly as shown 31 sq balsa in front of F9B Scrap balsa at rear of F5Band between F15 and F16 ...

Страница 32: ...FUSELAGE ASSY PICTURES 1 Add scrap balsa to support covering properly as shown 32 Add a piece of scrap balsa around bracket Add a piece of scrap balsa in front of stab Sand RF2 as shown ...

Страница 33: ...FUSELAGE ASSY PICTURES 1 Sand RF2 as shown 2 Glue a piece of 1 8 balsa over F9B to match RF2 and allow proper covering installation 33 ...

Страница 34: ...FUSELAGE ASSY PICTURES 1 Glue 2 scrap pieces of x 1 leading edge stock and shape as shown 2 Sand blocks to fuselage shape once the front fuselage sheeting is installed as shown 34 ...

Страница 35: ... pieces of 3 8 sq balsa to make ribs 4 Glue 3 8sq hardwood stick to trailing edge of rudder fin assembly 5 Trim top of hardwood flush with top of fin 6 Trim bottom of hardwood flush with bottom of fuselage tail 7 Drill 1 hole 1 8dia at location shown 8 Glue R1E as shown 35 R1A R1B R1C R1F 1 R1E R1H R1G Ribs ...

Страница 36: ... the rudder 3 Cut a 3 8sq balsa stick 15 inches long 4 Glue a 3 8 sq balsa stick and trim both end 5 Round trailing edge and bevel 45 degrees on each side of leading edge 36 R2A R2B R2C Bevel leading edge R2D 5 8 DIA DOWEL 3 8 BALSA TRAILING EDGE Round trailing edge ...

Страница 37: ...STEP32c 1 Mark lines as shown on both fin and rudder for Robart hinges 6 required 7 Drill 3 16 dia holes using Robart drill jig on both fin and rudder 37 3 8 2 5 places ...

Страница 38: ...STEP32d 1 Glue 2 R1D on each side of rudder fin assembly as shown 2 Glue F21 as shown 38 R1D F21 R1D R1D ...

Страница 39: ...F20 as shown 4 Cut 4 X X 1 15 16 long hardwood sticks 5 Glue hardwood sticks in slots found in F20 and F21 They will be used to support elevator servos 6 Sand F26 face to make them parallel to fuselage side 7 Glue 1 F26 on each sides of F9B 39 90 degrees F20 Hardwood sticks F26 Sand face prior gluing to make them parallel to fuselage side ...

Страница 40: ...kept in place using No2 x screws Use holes in F19L and F19R as guide to drill holes in rudder fin post and F26 parts located on each sides of F9B 5 Sand R1D flush to F19L and F19R 40 F19L left side cover F19R right side cover R1D ...

Страница 41: ...Elevator servos installation 41 left side servo Right servo Elevator servos view from rear with F19L and F19R installed ...

Страница 42: ...STEP35 1 Glue F15A F15B and F15C inside F15 on both sides of fuselage Right side parts not shown for clarity These parts will support the side windows 42 F15A F15B F15C F15B F15C Left side Right side ...

Страница 43: ...t 2 X X 14 5 8 long hardwood sticks 3 Glue the X hardwood sticks between F3 and F5 4 Install F27 rudder servo support and F28 fuel tank support using No2 X wood screws 43 X hardwood sticks 2 required F25 X hardwood sticks front end Flush with F3 F28 F27 ...

Страница 44: ...ation 1 Glue F25 over fuselage bottom as shown 2 Cut 2 X X 14 5 8 long hardwood sticks 3 Glue the X hardwood sticks between F3 and F5 4 Install F27 rudder servo support and F28 fuel tank support using No2 X wood screws 44 ...

Страница 45: ...ge They locate in large slots in FS 3 Glue 1 F37 on each sides of fuselage as shown Hole in F37 indicate the front There are two locator design in F4 and F8 to align F37 properly 45 3 8 sq balsa sticks 5 required F37 on both sides F36 F37 F4 locating slot F37 front Ref hole F8 locating slot ...

Страница 46: ...long balsa sheeting 2 Glue pieces of balsa strips as indicated by arrows Balsa strips should be flush wit FB 46 Sand 3 8sq balsa stick flush with 1 8 X 3 8 balsa strip 1 8 X 3 8 balsa strip 3 8sq balsa stick FB 1 8 X 3 8 balsa strip flush with FB ...

Страница 47: ...1 8 X 3 8 x36 inches long balsa sheeting 2 Glue pieces of balsa strips as indicated by arrows on right side as shown 3 Glue 2 F12 as shown 4 using 4 X long screws install F19L and F19R 47 F12 both sides F19L F19R on right side ...

Страница 48: ...l tail wheel as shown using screw provided with tail wheel 2 Install Landing gear using 6 8 32 SHCS and 6 8 washers Use Locktite to secure main landing gear once the plane is finish 48 8 32 SHCS and 8 washers 6 places ...

Страница 49: ...STEP40 1 Glue wing tube and trim flush to F14 49 Glue wing tube and trim flush to F14 ...

Страница 50: ...STAB AND ELEVATOR ASSEMBLY Follow directions carefully Always dry fit first Assemble all components on a flat building board 50 ...

Страница 51: ... 8 sq hardwood stick and trim both end 5 Round leading edge 6 Align with the fin and mark location of Robart hinges 5 required 7 Drill 3 16 dia holes using Robart drill jig on both fin and rudder 51 E1 E2 Round leading edge 3 8SQ HARDWOOD STICK 1 8 dia holes Located at inch from end of stab Both sides ...

Страница 52: ... Cut a 3 8sq hardwood stick 23 inches long 3 Glue a 3 8 sq hardwood stick and trim both end 4 Round leading edge 5 Drill 2 holes 1 8 dia located at inch from end of hardwood stick 52 E3 E4 Bevel leading edge 5 8DIA HARDWOOD DOWEL E5 Round trailing edge ...

Страница 53: ...STAB AND ELEVATOR ASSEMBLY STEP3 1 Mark lines on both stab and elevators to align Robart hinges as shown 2 Drill 3 16 dia holes using Robart drill jig on both fin and rudder 53 3 8 3 7 16 3 7 16 3 8 ...

Страница 54: ...STAB INSTALLATION Follow directions carefully Always dry fit first Assemble all components on a flat building board 54 ...

Страница 55: ...b into slot found in rudder fin 2 Slightly lift on side of the stab to insert glue under on both side 3 Align carefully in both planes and secure while glue is bonding 55 STAB ASSY 90 degrees 90 degrees Plane 2 Plane 1 Slide stab in slot ...

Страница 56: ...WING ASSEMBLY LEFT WING SHOWN IN INSTRUCTION INVERT FOR RIGHT WING Follow directions carefully Always dry fit first Assemble all components on a flat building board 56 ...

Страница 57: ...emble 1 Assembly of WJ4 and WJ5 with WJ5 on the right 4 Install WJ1 and WJ3 as shown 5 Slide WJ2 in the center slots as shown 6 Align jig with a straight edge And fix it to table using crews on WJ4 When is it properly squared an straight 57 WJ1 WJ2 WJ3 WJ5 WJ4 WJ4 WJ4 WJ5 WJ5 This assembly X3 This assembly X1 LEFT WING SHOWN ...

Страница 58: ...n W22 and W23 indicate top and near W5 4 Glue W22 to W19 and W23 to W20 as shown 5 Install small bracket using 4 40 SHCS X4 4 washer X8 and 4 40 locknuts X4 58 4 40 SHCS 5 8 long X2 4 washer X4 4 40 lock nut X2 Small bracket W5B W6A W5A W6 W5 LEFT WING SHOWN W19 W20 W22 W23 W6B 4 40 SHCS 5 8 long X2 4 washer X4 4 40 lock nut X2 Small hole indicate top of part near W5 W5 W5 ...

Страница 59: ...indicate top and near W8 5 Glue W36 in front of W17 and W37 on rear of W17 6 Glue W38 in front of W18 and W39 on rear of W18 7 Install large bracket using 4 40 SHCS X4 4 washer X8 and 4 40 locknuts X4 59 4 40 SHCS 1 1 4 long X2 4 washer X4 4 40 lock nut X2 Large bracket W8B W9A W8A W9 rib W8 rib LEFT WING SHOWN W17 W38 W36 W18 W9B 4 40 SHCS 1 1 4 long X2 4 washer X4 4 40 lock nut X2 Small hole ind...

Страница 60: ... Locate 1 x bottom main spar on slot found on WJ5 2 Glue ribs W1 up to W12 over bottom main spar as shown 2 Glue W9A and W9B on the inside of W9 rib as shown 60 W1 W2 W3 W4 W5 W6 assembly W7 W8 W9 assembly W10 W11 W12 Locate bottom main spar on slot LEFT WING SHOWN ...

Страница 61: ... ASSEMBLY STEP5 1 Glue top main spar over ribs 2 Glue W15 on front of ribs as shown Notice small hole in W15 indicate top and near W1 61 W15 Top main spar Samll hole indicate top and near W1 LEFT WING SHOWN ...

Страница 62: ... rear of ribs as shown Notice small hole in W14 indicate top and near W7 2 Trim main top spar to allow W13 to be slided in the assembly 3 Insert and glue W13 as shown 62 W14 Small hole indicate top and near W1 W7 W7 W13 LEFT WING SHOWN ...

Страница 63: ...WING ASSEMBLY STEP7 1 Glue 1 4sq balsa rear spar on top and bottom of wing as shown It must be glued all along W14 63 Top rear spar Bottom rear spar W14 LEFT WING SHOWN ...

Страница 64: ...WING ASSEMBLY STEP8 1 Glue wing servo wire tube between W1 and W9 2 Trim as shown 64 Wing servo wire tube W1 W9 Tube flush to W1 Tube trimmed from to W9 LEFT WING SHOWN ...

Страница 65: ...W8 and W9 5 Glue 10 W29 webbing at location shown W29 in front and rear of main spar up to rib W6 and single webbing for the remaining ribs Omit 1 W29 between W6 and W7 and 1 between W9 and W10 6 Glue 1 W24 webbing on front of main spar between W5 and W6 and 1 between W8 and W9 65 W31 W21 W21 Small hole indicate top near W1 W30 W31 W31 W32 Omit W31 Here W29 W29 W29 W24 W24 W29 W29 W29 W29 W29 W29 ...

Страница 66: ...be and apply glue to all ribs and webbing where the tube is Tube should ptotrude approximatively 1 16 from W5 rib 3 Trim tube flush to W1 rib 66 Wing tube Apply glue along all webbings top and bottom Apply glue to all ribs Wing tube 1 16 from W5 W5 LEFT WING SHOWN ...

Страница 67: ...WING ASSEMBLY STEP11 1 Glue W27 on outside of W5 2 Glue W28 on W27 67 W27 W28 WING ASSEMBLY STEP12a 1 Remove wing from jig 2 Trim main spars flush with W1 and W13 W13 W1 LEFT WING SHOWN ...

Страница 68: ...WING ASSEMBLY STEP12b 1 Glue 1 W29 webbing between W6 and W7 and 1 W29 between W9 and W10 2 Glue 1 W31 webbing between W6 and W7 68 W31 W29 W29 LEFT WING SHOWN ...

Страница 69: ...t and apply glue to keep in place 2 Glue W25 to W1 as shown 3 Glue W26 to W1 as shown 4 Cut 3 8dia dowel to 1 inch length 5 Glue 3 8dia dowel into W26 69 W25 W26 W1 W1 3 8dia dowel WING ASSEMBLY STEP14a W16 1 Glue W16 as shown LEFT WING SHOWN ...

Страница 70: ... ruler mark lines on W14 edge 2 Using scrap balsa build block wide as shown minimum 1 2 thick 3 Glue block center with marked lines on W14 70 Ruler alignment marks Angle located On W7 Mark lines Aileron hinge location ruler W7 Mark lines LEFT WING SHOWN ...

Страница 71: ... W12 and W13 Leading edge sheeting over main spar but leave 1 8 for best cap strip support as shown Trailing edge sheeting is 1 5 inch wide Sand leading edge sheeting flush to W15 and trailing edge sheeting flush to W14 and to ribs end 71 Sand sheeting flush to W15 1 8 clearance for cap strips Sand sheeting flush to W14 LEFT WING SHOWN ...

Страница 72: ... sheeting over main spar but leave 1 8 for best cap strip support as shown Trailing edge sheeting is 1 5 inch wide except between W7 and W9 where it must cover aileron servo mounting plate Sand leading edge sheeting flush to W15 and trailing edge sheeting flush to W14 and to ribs end 72 Sand sheeting flush to W15 1 8 clearance for cap strips Sand sheeting flush to W14 Make openings for strut brack...

Страница 73: ...WING ASSEMBLY STEP16b Aileron servo opening must clear area where servo is to be located for better servo installation 73 Make openings to clear servo mounting tabs LEFT WING SHOWN ...

Страница 74: ...WING ASSEMBLY STEP17 1 Using 1 8X1 2 balsa strips make cap strips for top and bottom as shown 74 LEFT WING SHOWN ...

Страница 75: ... Glue 1 balsa leading edge 2 Glue 3 8sq balsa trailing edge 3 Shape leading edge using W1 and W13 build in leading edge profile 4 Shape Trailing edge as shown 75 Trailing edge Leading edge Leading edge shape LEFT WING SHOWN ...

Страница 76: ...WING ASSEMBLY STEP19 1 Once the wing are covered glue W33 wing tip support 2 Glue wing tip over W33 76 W33 LEFT WING SHOWN ...

Страница 77: ...rface 2 Glue 7 WA2 9 WA3 and 1 WA4 as shown 3 Sand WA1 flus to front of ribs and to top of ribs at trailing edge 77 WA3 WA3 WA2 WA3 WA3 WA3 WA4 WA3 WA2 WA2 WA2 WA2 WA2 WA2 Sand trailing edge flush with ribs Sand trailing edge flush to front of ribs LEFT WING SHOWN ...

Страница 78: ...WA5 WING ASSEMBLY STEP20b 1 WA5 aileron leading edge 2 Sand WA5 bottom edge flush with bottom of WA1 78 Sand bottom edge flush to WA1 LEFT WING SHOWN ...

Страница 79: ...made of 3 8 sq balsa stick WING ASSEMBLY STEP21 1 Cut 2 strips of 1 8 balsa 21 inches long 2 Glue strips as shown 3 Trim flush with both sides of aileron 4 Glue atrailing edge made from 3 8sq balsa stick 79 Front strip LEFT WING SHOWN ...

Страница 80: ...X1 2 hardwood block inch long 4 Glue the hardwood block into slot found on WA4 5 Drill hole for aileron horn screw 80 Cap strip 1 2 radius Typical installation Once aileron is covered Apply epoxy glue in hole and screw Install screw in hole Cut top of screw to install other parts Trim excess screw if required Hardwood block LEFT WING SHOWN ...

Страница 81: ...Aileron hinge drill jig assembly 1 Glue WADJ1 on each side of WADJ2 as shown 2 Drill a 3 16 dia hole in the center of WADJ2 using a press drill 81 WADJ1 WADJ2 Locate drill jig on press drill table and align drill on V notch ...

Страница 82: ...s shown Notice the angle cut on the ruler should be near W7 end of aileron 2 Drill 5 3 16 dia holes as shown 82 Angle near W7 Ruler alignment marks Locate drill jig on press drill table and align drill on V notch Ruler flush To aileron edge Mark lines Aileron hinge location ruler Reference line ...

Страница 83: ... Aileron hinge drill jig assembly 1 Glue WDJ1 on each side of WDJ2 as shown 2 Drill a 3 16 dia hole in the center of WDJ2 using a press drill 83 WADJ1 WADJ2 Locate drill jig on press drill table and align drill on V notch ...

Страница 84: ...ion ruler mark lines on wing sheeting 2 Using WDJ1 wing drill jig ailgn on marked lines and drill 5 3 16 dia holes 84 Ruler alignment marks Angle located On W7 Mark lines Aileron hinge location ruler W7 LEFT WING SHOWN Marked lines Drill jig location ...

Страница 85: ...DOOR ASSEMBLY Follow directions carefully Always dry fit first Assemble all components on a flat building board 85 ...

Страница 86: ...5 and D8 to remove interference 3 AdjustD6 and D7 to remove interference 4 Glue on D1 parts D5 D6 D7 and D8 5 Glue balsa filler as shown and sand flush 86 Adjust D6 and D7 here D6 LEFT WING SHOWN D1 Drill jig location D5 D7 D8 Adjust D5 and D8 here Balsa filler Sand flush ...

Страница 87: ...R ASSEMBLY STEP2 1 Glue on D3 over D4as shown 2 Glue D3 and d4 assembly over STEP1 assembly 3 Glue D2 on assembly 4 Once plane is covered glue window in frame 87 LEFT WING SHOWN D3 Drill jig location D4 D2 ...

Страница 88: ...DOOR ASSY PICTURES 88 ...

Страница 89: ...DOOR ASSY 89 Add balsa blocks between lower door panels to support hinges Hinge holes located in fuselage front door frame Add 3 8sq balsa sticks around door frame ...

Страница 90: ...G INSTALLATION 90 The following pictures explain the installation of the cowling Pictures shown are from the 35 Decathlon but the method is similar Builder may choose different method for cowling installation ...

Страница 91: ...cut the front face of the cowling to clear the hub 1 8 all around Install engine to verify proper clearance Open both intake vents 2 Scale like method Make the hole to clear engine hub first using a Dremel or equivalent rotary tool Using a thin saw or a thin rotary cutter cut the lower portion of the face at 45 degrees on both sides Keep the removed part It will be glued to the bottom cowling Easy...

Страница 92: ...he rectangular cooler hole located under the light You can choose to open the light as well depending what you want to do with it 2 Measure engine exhaust pipes locations and open up the cowling It is much safer to enlarge the holes slowly to avoid enlarging the holes too much ...

Страница 93: ...d laminating epoxy for the next step 2 Apply epoxy glue inside the cowling to cover the added part and the area of the bottom cowling adjacent to it 3 Place a piece of fiber glass cloth over the glue and make the glue penetrate the fiber Make sure it is square with the side edge of the cowling 4 Secure the assembly until it is dry With this type of epoxy It usually take over 8 hours to set 5 When ...

Страница 94: ... 1 prepare 2 piece of 1 4 X 1 2 hardwood stick 8 1 2 long 2 Using laminating epoxy glue the sticks INSIDE the cowling fiberglass flange This flange is made wider than necessary and will be trimmed after glue is dry Apply clamps while the epoxy cure 3 Trim the excess flange material flush to the hardwood stick on both sides ...

Страница 95: ...ther using masking tape 2 Measure at front and rear end of the cowling MAKE THE LINE OVER THE TOP COWLING AREA 3 Make a line between both marks and locate the first hole at from rear end of cowling 4 Mark other holes at 1 15 16 spacing TOP BOTTOM TOP TOP TOP ...

Страница 96: ...cations marked Drill through both parts 6 Separate parts and enlarge holes in bottom cowling part to 5 32 diameter 7 Install 10 4 40 T nuts on flange both sides and secure them with glue 8 Reassemble both cowling halves using 4 40 X long for next step TOP BOTTOM BOTTOM ...

Страница 97: ...e should fit as shown in this picture and locate the bottom part properly 11 Locate and glue the hardwood parts using laminating epoxy made thicker using sand dust inside the top cowling Let cure for 8 hours 12 Mark location of the blocks on a piece of tape placed in front of cowling 13 Drill 7 64 diameter holes at locations 14 Separate parts ...

Страница 98: ...oles in top cowling blocks to 5 32 diameter 16 Install 1 4 40 T nut in each holes 17 Use 12 4 40 button head cap screws long to assemble both cowling parts together 18 Use 8 4 40 socket cap screws long and 1 long to assemble cowling to fuselage TOP ...

Страница 99: ...wood blocks 1 Glue liteply support made from scrap plywood as shown for each bracket assembly 2 Glue side plates on each assembly as shown 3 Using scrap balsa make 1 piece 1 X 1 for each assembly and glue over as shown 4 Sand a 45 degrees angle on each assembly as shown 5 Make countersink maximum depth 3 32 approx 2 25mm Sand 45 degrees Make countersink for 4 countersink head screws ...

Страница 100: ...t block scrap liteply and balsa 2 Locate the top center block It will be glued in place later For now use small tack of glue to keep it in place 3 Light sand the balsa block over each block to have the proper shape It will need to be adjusted to ensure proper fit between the dashboard and the top cowling part Top bracket assembly not required for the 25 Decathlon ...

Страница 101: ...ing part over the brackets and hold in place using masking tape 2 Measure each side to make sure of proper alignment Make marks to locate the top cowling 3 If the fit between the dashboard and the top cowling is not perfect lightly sand the balsa block until fit is good Do not sand the 1 8 sheeting around front of fuselage ...

Страница 102: ... tape 1 Apply masking tape around the front of the dashboard and mark location of the center of each top brackets 2 Install the top cowling apply tape on the edge of the cowling and transfer marks from dashboard locations to the cowling These marks will define hole location 3 Measure from F1 face and mark holes center at 5 places on top cowling Measure at each locations ...

Страница 103: ...rt brackets 2 Using a 5 32 diameter drill 3 97mm enlarge holes made in support brackets only 3 Install 1 4 40 T nut inside each assembly and glue it in place 4 Untack the top center bracket install 4 40 T nut and glue bracket in place with carpenter glue or epoxy 4 40 T nut Drill 7 64 Diameter through cowling and support bracket Glue the top center bracket using carpenter glue or laminating epoxy ...

Страница 104: ...NG INSTALLATION 7 104 Use 8 4 40 socket cap screw long and 1 long top center bolt to secure the cowling to the fuselage as shown If required sand the fuselage 1 8 balsa sheeting to match the cowling properly ...

Страница 105: ...105 1 Install 2 fairing made from scrap 1 8 plywood as shown in picture below Notice the cutout made on the cowling to increase air exit COWLING INSTALLATION 8 ...

Страница 106: ...proximatively 2 Using a band saw cut in REAR strut a slot 1 1 8 inches long at one end 3 32 wide approximatively 3 using band saw remove excess material at L E and T E of each strut front and rear 4 Round leading and trailing edge using coarse sand paper 5 Install large strut bracket on the slot with front edge flush with leading edge of FRONT strut 6 Drill 2 holes 1 8 diameter located inch from l...

Страница 107: ... strut 2 Mark location of holes in the REAR strut using the small aluminium bracket as hole location jig Bracket should be flush with leading edge of REAR strut Make sure to use holes that are at of each other 3 Drill 2 holes 1 8 dia 1 2 4 40 X 3 4 SHCS 2 4 40 locknut 2 4 washer 4 ...

Страница 108: ...asher 4 2 Trim FRONT strut at a length of 28 5 8 3 Trim REAR strut at a length of 28 1 8 4 Cut end of FRONT strut as shown to fit between front wing brackets 5 Cut end of REAR strut as shown to fit between rear wing brackets 28 1 8 7 8 1 2 7 8 12deg 5 8 1 8 1 2 FRONT strut 28 5 8 REAR strut Strut leading edge Strut leading edge ...

Страница 109: ...STRUTS INSTALLATION 2b 109 Front strut end shape Round end of strut as shown Rear strut end shape Round end of strut as shown ...

Страница 110: ...STRUTS INSTALLATION 3 110 1 Drill 1 8 dia hole in the end of the FRONT strut as shown 2 Drill 1 8 dia hole in the center of REAR strut as shown FRONT strut REAR strut end 1 4 1 4 ...

Страница 111: ...g and inch wide Round each end 2 Wrap the strap over the end of the FRONT strut 3 Drill 2 holes through the strap and the FRONT strut First hole at from end second hole at from first hole 4 Use 4 40 SHCS 1 long to secure strap to strut end Repeat step for the other wing strut 3 4 ...

Страница 112: ...d below Use the tmplate provided to make the bracket 2 Wrap the strap over the end of the REAR strut 3 Drill 2 holes through the strap and the REAR strut First hole at from end second hole at from first hole 4 Use 4 40 SHCS long to secure strap to strut end Repeat step for the other wing strut ...

Страница 113: ... be perpendicular to wing bottom so the hole must be made to suit this requirement Center of strut Leading edge 2 Drill 1 8 dia at 15 5 8 from the end near the fuselage on the REAR strut as shown in picture Interstruts must be perpendicular to wing bottom so the hole must be made to suit this requirement Measure from here Measure from here ...

Страница 114: ...STRUTS INSTALLATION 7 114 1 Make 2 interstrut brackets from 020 aluminium as per sketch shown below for each wings 2 Bend each bracket 65 degrees up in the center of bracket 65 deg ...

Страница 115: ...trut using 1 4 40 SHCS 3 8 long with 1 4 40 locknut and 3 4 washers 3 Install strut assembly to the airframe using 6 32 SHCS long with 1 6 32 locknut and 2 6 washers on each sides 4 Attach end of struts to the wing using 2 4 40 SHCS 1 long with 2 4 40 locknuts and 4 4 washers 4 40 SHCS 3 8 long 6 32 SHCS long 4 40 SHCS 1 long 4 40 SHCS 1 long ...

Страница 116: ...lat 3 Use 1 4 40 SHCS 1 long to secure front interstrut bracket to front strut 4 Use 1 4 40 SHCS long to secure rear interstrut bracket to rear strut FRONT INTERSTRUT cut tube to 4 5 8 long holes spacing of 4 3 16 REAR INTERSTRUT cut tube to 5 11 16 long holes spacing of 5 3 8 INTER TUBE cut tube to 6 1 8 long holes spacing of 5 11 16 Drill all holes using 1 8 dia drill Interstrut bracket on front...

Страница 117: ...TION 10a 117 1 Install interstrut tubes as shown Use 4 4 40 SHCS 3 8 long with 4 4 40 locknuts and 8 4 washers on each wings Front Interstrut Inter tube Rear Interstrut Wing Interstrut bracket Wing Interstrut bracket ...

Страница 118: ...STRUTS INSTALLATION 10b 118 Front view of interstruts installation ...

Страница 119: ...9 1 Prior gluing the front windshield dry fit over the fuselage Use tape to hold in place 2 Secure the top of window using 5 4X screws on the hardwood stick located in front of F2B Make sure it align perfectly with F14 outer wall ...

Страница 120: ...o much heat since it may distort the windshield 2 Once fit is good start gluing the front center portion using Pacer Formula560 canopy glue or equivalent glue Apply tape to hold in place 3 Once the center area is dry apply glue to both lower side of the windshield and install 4X screws 5 on each side as shown in picture ...

Страница 121: ...WINDSHIELD INSTALLATION 3 121 1 Once the windshield is secure use automotive trim tape to finish the contour of the windshield 2 Install top rear window using 14 4 X screws as shown in picture ...

Страница 122: ... one that is going in the door aperture The other one is installed in the fuselage left side 2 Glue both front window in their proper location using Formula560 glue or equivalent 3 Glue both rear window on each sides of the fuselage Door windows is a bit smaller fuselage windows rear windows on both side ...

Страница 123: ...ES INSTALLATION 1 123 1 there are 8 flying wire brackets sullivan tabs and one larger braket that is located under the rear end of the fuselage rear flying wire bracket Sullivan tabs used as flying wire brackets ...

Страница 124: ...end sullivan tabs as shown in order to have straight line between both ends of wire 4 Use 3 4 40 X SHCS and install tabs on both sides of each stabs and rudder fin with 3 4 40 locknuts Use 2 4 40 X 3 8 SHCS to fix tabs to fuselage bracket with 2 4 40 locknuts 5 Use steel cable from Sullivan product to make flying wires as shown below One end must be adjustable Cable lock Sullivan tabs Sullivan cle...

Страница 125: ...FLYING WIRES INSTALLATION 3 125 Pictures below indicates the way that flying wires are installed Do not adjust them so that they are too tight They should be straight but not too tight ...

Страница 126: ...tip first Wing tip will be glued over wing tip support 2 Prior gluing anything dry fit the W33 rib inside each wing tip It is required to sand the trailing edge taper to fit the wing tip Carefully locate W33 over W13 Use wing tip to align W33 W33 ...

Страница 127: ...ng tip over W33 and check fit between wing tip and wing profile You may have to add shim to W33 or to sand either the wing tip inner area or W33 outer profile a little bit so that wing tip fit perfectly To sand W33 it is better to remove it from wing assembly ...

Страница 128: ...ION 3 128 5 When the wing tip match the wing profile properly apply glue to W33 and glue it in place 6 Last step is to glue the wing tip or use small screws all around if you want it removable screws not provided in kit ...

Страница 129: ...r 8 32 screw in hardwood aileron block approximatively inch deep B Install horn and locknut on 8 32 screw Screw them until they reach the head of the screw C Apply glue in hole and install 8 32 approximatively inch deep D Make the required linkage as shown on pictures D Once the glue is set trim the head of the screw to proper length ...

Страница 130: ... inches 8 32 SHCS and plastic washer and install it in 3 16 dia hole found in the elevator B Install lock nut and horn on the other side to proper position C Make the required linkage as shown on pictures Notice that the horn may need to be trimmed and redrilled so the pivot point is inline with elevator leading edge ...

Страница 131: ...des in kit A Use 1 3 inches 8 32 threaded rod and 2 locknuts and install it in 3 16 dia hole found in the rudder B Install 2 horns on the each sides to proper position C Make the required pull pull cables as shown on pictures Notice that the horn may need to be trimmed and redrilled so the pivot point is inline with rudder leading edge ...

Страница 132: ...d inside the fuselage but there will be no easy access in case of problem with these servos once the plane is completed Depending on the engine used servos installation may differ significantly inside the fuselage installation that can be used on engine with rear carburetor Example of installation for a twin 50cc engine with carburetor under engine ...

Страница 133: ...TANK INSTALLATION 133 Tank should be installed on the plate and approximatively centered on the CG We usually suggest to use velcro under the tank and a tie wrap to secure it to mounting plate ...

Страница 134: ...ng style Final weight of the plane is 20 22 pounds depending on equipment engine used Use standard servos suitable for 50CC engine aircraft Recommended engines DLE30 up to DLE55 DA50 MOKI 45 NGH GT35 PTERODACTYL 36 RCGF32 to 45 single or 40 or 50 TWIN ROTO35 ZDZ40 to 50 all available from AMR RC It is strongly recommended to stay within this range Failure to do this may damage the airplane since i...

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