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Z I P P M A N U FA C T U R I N G

Zippkits R/C Boats

BUILDING INSTRUCTIONS

2007, 2008 Zipp Manufacturing

750 Ball Road • Frankfort, New York 13340

(866) 922-9477

www.zippkits.com

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Страница 1: ...Z I P P M A N U FA C T U R I N G Zippkits R C Boats BUILDING INSTRUCTIONS 2007 2008 Zipp Manufacturing 750 Ball Road Frankfort New York 13340 866 922 9477 www zippkits com...

Страница 2: ...s 11 Sponson Non Trips 13 Sponson Bottoms 12 Rear Non Trips 17 Sealing Interior 19 S E C T I O N 3 E Q U I P M E N T Radio Box 15 Fuel Tank 31 Running Hardware 26 Engine mounting 30 Shaft and Stuffing...

Страница 3: ...children 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 th...

Страница 4: ...to an aerodynamically sound design You can build this boat without having the engine or radio but it does make it easier to have them available when you build You can use any gasoline engine as long...

Страница 5: ...rit paper Drill with bits Right angle drill or attachment Square FLAT Workbench 3 wood blocks x 2 x 10 1x stock or ply 3 4x 10x 48 MDF or ply 1 ounce Thin CA glue and accelerator Good quality 30 minut...

Страница 6: ...ne Tuned pipe 2 channel surface radio with 1 standard and 1 heavy duty servo 100 in oz minimum Throttle pushrod 2 56 or 4 40 Size with Clevises 2 4 40x12 Pushrods and a OD carbon pushrod 2 pushrod sea...

Страница 7: ...s flat The entire boat will be built on this so make it right The Frame We are ready to start the build Let s identify the parts in the sheets Don t remove the parts until you actually need them as so...

Страница 8: ...R I V E T T R O C K E T T 6...

Страница 9: ...E T T R O C K E T T 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 applica...

Страница 10: ...much easier to sand the parts once they are out of the sheet While the parts are still in their sheets use a pencil to mark each part with the name and which side is right or left as the parts only fi...

Страница 11: ...turn fin doubler is glued to the proper side of bulkhead 3 Make sure the doubler will be on the front inside of the bulkhead When you are sure you have it correct glue the doubler to the bulkhead wit...

Страница 12: ...ur building board with waxed paper or clear plastic wrap We don t want to glue the boat to the building board Start by assembling bulkheads 1 2 and 3 to the side stringers Make sure the bulkheads are...

Страница 13: ...bulkhead 3 being careful to align the bottom part flush with the step in the side stringer Fit bulkheads 4 and 5 making sure that they fit tightly to the side stringers Wrap a rubber band around bulk...

Страница 14: ...d correctly If you are not sure check it against bulkhead 1 Putting it together Slip the framework over the bottom and slip the tabs of bulkheads 4 and 5 into the slots in the bottom Place weights on...

Страница 15: ...k under bulkhead 1 for support Double glue bulkheads 4 and 5 to the sides and bottom Use accelerator Wrap your 3 4x2x10 gluing block with waxed paper Slip it under bulkhead 1 to support the bottom whi...

Страница 16: ...e center area of bulkhead 2 as it will be removed later DO NOT glue bulkhead 3 to the bottom yet Glue the nose portion of the bottom to the sides aligning the front tip of the sides to the bottom Use...

Страница 17: ...as a cutout for the carb Test fit the rails as follows Put the right rail in the slot in bulkhead 1 Push the rail against bulkhead 3 so that it bows back slightly The rail will snap into place Do the...

Страница 18: ...ms and sides Start with the side chine Slip it into the notches in the outside edge of the bulkheads Put the front tab into the side stringer seating it fully If the chine doesn t seem to fit correctl...

Страница 19: ...ime to get the sponson transoms square as the turn fin will be bolted to one of them If not square the boat will not track straight Sponson Non Trip With the hull upside down use your wood plane to be...

Страница 20: ...30 minute epoxy Using your special epoxy brush put a coat of epoxy on the chines and bulkheads where the sides will touch Also seal the chines at this time as they will be difficult to seal after the...

Страница 21: ...east 2 hours Repeat on other side When the non trip sides have fully cured remove the tape and clamps Sponson Bottoms Plane and sand the sides even with the sponson bottom Take your time here as this...

Страница 22: ...eft and right inside didn t you Quickly tape the sponson bottoms tightly to the sponsons Be sure that the inside edge of the sponson bottom is aligned as well as you can get it It should be flush Also...

Страница 23: ...weighted on gluing block so that it remains flat Sponson bottom resting squarely on bench We just want to make sure that both sponsons are resting squarely on the table with the transom shimmed inch...

Страница 24: ...ile the bottom sheet cures Radio Box Remove all of the radio box parts Two long sides two short sides the top and bottom as well as the 1 8 ply top with lid Sand all the parts smooth with 80 Lay a pie...

Страница 25: ...ng on top Put glue on the edges and join the two box halves on the bench Lightly sand the bottom of the box Glue on the bottom Lightly sand the top Glue the radio box top on This is the 1 8 inch Birch...

Страница 26: ...emove the lid from the 1 8 ply radio box top Sand the edges smooth Glue the 1 8 ply top to the radio box It has a slightly larger hole for the lid so try to center it so that the lip is even all aroun...

Страница 27: ...so the part doesn t become a permanent part of your bench When dry sand each mount smooth with 80 Get your servos Hold the servo at the end of the mount mark the hole locations in the ply Be sure to l...

Страница 28: ...way as you did the rudder servo Drill 3 8 holes where the pushrods will exit Remove everything from the radio box and coat the inside and outside with finishing resin Be careful not to get any buildu...

Страница 29: ...p sides are designed to go inside of the hull between the sides and bottom They must be beveled in order to fit Hold one of the rear non trips near the back of the hull and mark it for the bevels need...

Страница 30: ...rip in place Rear View of non trips installed Transom being glued in place Transom When the rear non trips are done sand the rear of bulkhead 6 Glue the transom to the rear of bulkhead 6 using 30 minu...

Страница 31: ...1 8 inch to the bottom Aim the engine towards the hole in bulkhead 3 Use a inch rod or long bolt to align the engine to the hull Push the rod from the bottom through the slot and hole in bulkhead 3 an...

Страница 32: ...ube The stuffing tube is a piece of 11 32 brass tubing about 3 1 2 inches long Rough up the outside of the tube with coarse sandpaper Slip the tube onto the 5 16 tube until it is within inch of the co...

Страница 33: ...ve anything for at least two hours Deck Supports Sand the two deck supports Glue the deck supports into the notches in the bulkheads using medium CA Start at the rear and glue to each bulkhead When yo...

Страница 34: ...uch It s pretty funny to get the inside sealed 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...

Страница 35: ...rk a centerline along the length of both mounts On one of the mounts mark lines from both ends On the other mount mark the center Drill 3 16 holes at the intersections of your lines Hold the rear moun...

Страница 36: ...nd lock washers bolt the mounts to the radio box Sand the bottoms of the mounts Cut 3 little pieces of masking tape about inch square Put these on the blind nuts so that epoxy cannot get into the nut...

Страница 37: ...rut to the center line and tighten the screw Take a step back and eyeball the strut to make sure it and your center line are straight If all looks good mark and drill the other 3 holes Mount the rudde...

Страница 38: ...tube where the stuffing tube ends Remove the shaft tube and heat the area around the mark with a torch until it changes color This will anneal the brass tubing making it soft and easy to bend Only hea...

Страница 39: ...of the drive dog Subtract inch from this measurement This is the amount to cut off the front of the cable to leave a inch drive dog to strut gap Exhaust We used a quiet pipe in our hydro and recommend...

Страница 40: ...ttle is setup your throttle servo will either be on the right or left of the radio box We used the straight pushrod vertical bell crank throttle linkage on the prototype and prefer it Whatever method...

Страница 41: ...r view Turn fin Assemble the turn fin to the bracket so that it is on the inside of the bracket If you mount the fin on the outside of the bracket it would cause the water to lift the right sponson in...

Страница 42: ...ply deck with the epoxy glass cowling glued to it You should have already sealed one side of the cowl deck Glue the two halves together Do not adjust the way the decks come together as they are desig...

Страница 43: ...ral hours or overnight You can spray the lite ply deck again after a few hours if you want It will help the cowl deck to conform to the compound curve of the hull While the deck is drying grab the epo...

Страница 44: ...otation as epoxy glass does not float It s not a question of if you will lose your cowling it s when Use white polystyrene foam and 5 minute epoxy to glue it into the cowling You must block the air fr...

Страница 45: ...ough to the air exit carrying very little heat with it We need it to go into the front and go around the bottom of the hull before going up to the dashboard See page 59 for details Top Deck This is wh...

Страница 46: ...mp one deck to the deck support near the front and rear Line up the rear of the sponson with the deck and line up the deck inside edge with the centerline you drew on the deck support When the deck is...

Страница 47: ...d or piece of thin plastic or wood for the next steps Mix about ounce of epoxy finishing resin Using a squeegee or credit card coat the bottom of the deck with resin This seals the deck bottom Use you...

Страница 48: ...d sand the deck flush and keep the radius at the rear of the sponsons smooth The nose should be rounded off and blunt Do not make the nose sharp as this will make the hull unpredictable at speed Keep...

Страница 49: ...Continue taping the front portion Make sure that the inside edge of the deck matches your centerline on the deck support It is important that the space between the deck halves is 6 1 2 inches as this...

Страница 50: ...procedure on the other side Make sure the hull stays weighted on the bench until the deck center is done Glue the sponson decks on the same way You may find it easier to bend these decks if you soak...

Страница 51: ...t this hatch based on the location of your engine The hatch should measure about 3 1 4 by 1 1 4 inches Carefully measure and mark the position of the hatch directly on the deck Use a fine tooth razor...

Страница 52: ...cured test fit the hatch in place It should be fully retained by the cowling Ride Pads The ride pads go on the bottom of both sponsons and are the actual ride surface for the hull These lift the hull...

Страница 53: ...e and rear The hull is now ready for finishing Note that the photos show ride pads being installed on a finished boat but the same thing applies to the bare hull Finishing Sand the entire hull with 80...

Страница 54: ...allenging but will use far less resin and be faster to cover When you are sure that all areas on the top and sides are covered let it cure overnight When cured sand lightly with 80 Just make it smooth...

Страница 55: ...mpressed 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 lightly wipe all surfaces Spray your color coats When cured...

Страница 56: ...way in Leave the strut loose in the brackets Put the boat on a flat surface You can hang the turn fin over the side of the table Block up the transom 7 8 inch from the table Push the strut to the tab...

Страница 57: ...collet Leave a inch gap between the drive dog and strut Tighten the collet Wrap your receiver failsafe and battery pack in foam rubber Mount the switch Turn the transmitter on first then the receiver...

Страница 58: ...mly attached Use those teeny little tie wraps at each fitting Center of Gravity The CG is very important to 1 inch behind the sponson transom Check the CG with everything installed and no fuel in the...

Страница 59: ...gine This will help to break in the strut bushings At the pond Make sure your transmitter and receiver batteries are fresh or fully charged Do a range check with your transmitter antenna down and note...

Страница 60: ...self 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 Notice how the boat rides in the straights Does it lean or pull to one side Is th...

Страница 61: ...R I V E T T R O C K E T T 59...

Страница 62: ...R I V E T T R O C K E T T 60 Hatch support detail...

Страница 63: ...R I V E T T R O C K E T T 61...

Страница 64: ...R I V E T T R O C K E T T 62...

Страница 65: ...unstable Strut too high CG too far back Boat needs left trim to go straight Prop walk Prop walk Prop walk Turn fin not aligned correctly Prop walk Boat slides too much in turns Turn fin bent Turn fin...

Страница 66: ...the 7 8 inch measurement is a starting point The goal is to get the hull to ride level or just a teeny bit tail high at full speed If you have to push the strut down to 1 inch or 3 inches to get the...

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