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38) Start by putting the Fuel Tank together.
a) Locate the Rubber Stopper Assembly. There are three nylon
tubes going through the rubber stopper. Orient the stopper so
that one of the tubes is towards the top and then bend that tube
up at a 45-degree angle. Do not apply heat to the tube - it will
bend without heat. Just overbend it to nearly 90-degrees and then
let it relax, to see where it will end up. Repeat if necessary until
the tube will stay at 45-degrees.
b) Attach the metal Fuel Pick-Up Weight on one end of the sil-
icone Fuel Line Tubing that goes inside the tank. Cut the other
end of the fuel line tubing to a length that will allow the clunk to
reach the back of the tank, without getting stuck on the walls of
the tank. Test fit in the tank and adjust as necessary. With the
stopper assembly in place, the fuel clunk should sit just in front of
the rear of the tank and move freely inside the tank. If not pull the
assembly back out and trim the tubing back until the stopper
moves freely. The top of the vent tube should rest just below the
top of the tank. It should not touch the top of the tank.
c) Once you are satisfied with the fit of both the fuel clunk line
and the vent line you can tighten the machine screw to expand
the rubber stopper and seal the stopper in the tank. Do not over
tighten the screw as it can cause the tank to split. Attach three 6-
inch lengths of silicone fuel tubing (not furnished) to the tank and
label them appropriately as FILL, CARB, and VENT so you can
identify them after the tank is installed in the airplane.
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39) Install the tank in the fuselage.
a) Install the two hook-&-loop (Velcro®) straps through the
slots in the plywood fuel tank tray. You may find it useful to use a
thin straight edge such as a small ruler inserted into the second
slot to help guide the strap back up to the top of the tray.
b) Set the plywood fuel tank support in place, but do not glue.
c) Install the fuel tank through the back of the plywood tank
support. Push the tank all the way up to the back of the firewall,
pulling the 3 fuel lines through the firewall as you go.
d) Strap the tank in place with the hook-&-loop straps.
e) Glue the plywood fuel tank support in place, inserting its
bottom tabs into the slots in the plywood fuel tank tray. We sug-
gest you only spot glue the tank support in place at the top so it
can be removed later if you ever need to service the fuel tank.
f) Glue the balsa block fuel tank stop in place on the plywood
tank tray, up against the rear end of the tank.
❑
40) Bolt the two Nylon Engine Mounts on the front of the fire-
wall, using M4 x 30mm Bolts and M4 Flat Washers provided. Note
that the blind nuts are already installed in the back of the firewall.
❑
41) Set your engine in place on the beams of the engine
mounts. Slide the engine forward or aft on the engine mounts until
the front of the engine's thrust washer is 5-9/16" from the front of
the firewall. Double check to make sure that the engine is pointing
exactly straight forward, and then mark the locations of the engine
mounting holes onto the beams of the engine mounts, using a
center punch or sharpened nail.
❑
42) Now set your engine aside and unbolt the engine mounts
from the firewall. Drill clearance holes for your engine mounting
bolts all the way thru the engine mount beams at the four locations
you marked in the previous step.
IMPORTANT: Do not drill and
tap these engine mounts. Doing so may weaken them and
cause failure.
Use steel mounting bolts, flat washers, and nylon
insert lock nuts (not provided).
Drill 5/32" dia. holes if you are using 6-32 mounting bolts.
TIP: Secure the engine mounts in a vise while you drill the holes.
If at all possible use a drill press instead of a hand drill - the job
will be much easier and the holes will be straighter.
❑
43) 2-STROKE THROTTLE PUSHROD
a) Mount your throttle servo in the middle opening of the servo
tray in the fuselage.
b) The supplied throttle pushrod assembly consists of a wire
pushrod running inside a nylon pushrod tube. On the threaded
end of the pushrod you will have a metal RC clevis. For a typical
2-stroke installation we prefer to clip this end to engine’s throttle
arm. The plain end of the pushrod wire will connect to the throttle
servo arm using a metal pushrod keeper, which allows you to eas-
ily adjust the overall length of the pushrod.
c) Determine which side of the airplane your throttle pushrod
will be on. Typically for 2-stroke engines it will be on the right side
of the fuselage. For 4-stroke engines it is often on the left side.
Then determine the exact route your pushrod will take to connect
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