Global ARF Ultimate Biplane
Transcription
Global ARF Ultimate Biplane
.46 SIZE AEROBATIC ARF PERFORMANCE BIPLANE Instructions for Final Assembly Would you like to fly your own Ultimate Biplane? Do you want to be flying in a weekend? Are you ready for an aerobatic 46 size performance biplane? Then you’ve chosen wisely. The Global ARF Ultimate was made for you. Features like an all balsa and plywood built up airframe, just like you'd do it yourself from a kit. A generous tail section combined with a long fuselage moment and swept wings make this an aerobatic performer that you'll always want to fly. A super strong metal wing center cabane system with outer plywood interplane struts hold everything together when you're performing snap rolls and inverted spins. To go along with this we've provided a prepainted four color cowling, prepainted wheel pants and a clear molded canopy. There is no other aerobatic biplane in it's class that is easier to assemble or that flys better. We know you’ll enjoy building the Ultimate, but you bought this airplane to fly. And that's what it does best. Set up for sport flying, it’s predictable and tracks like it's on rails. Deceivingly easy to fly, change the set-up parameters and you’ll push the envelope like an experienced airshow performer. Complete inverted flat spins and torque rolls like you’ve never performed before! Version V1.0 3-99 Kit # 123820 All Contents © Copyright 1999 1 TABLE OF CONTENTS Kit Contents....................................................2 Additional Items Required...............................3 Tools and Supplies Needed..............................3 Field Support Equipment Needed.....................3 Metric Conversion Chart..................................3 Bottom Wing Mounting...................................4 Align the Bottom Wing.............................4 Installing the Blind Nuts...........................4 Installing the Wing Bolt Doubler...............5 Installing the Wing....................................5 Horizontal Stabilizer Mounting........................5 Align the Horizontal Stabilizer..................5 Mounting the Horizontal Stabilizer............6 Vertical Stabilizer Mounting...........................7 Align the Vertical Stabilizer......................7 Mounting the Vertical Stabilizer................7 Top Wing Mounting........................................7 Align the Top Wing...................................7 Installing the Interplane Struts...................8 Mounting the Top Wing............................9 Control Surface Installation..............................9 Hinge the Elevator Halves.........................9 Install the Tail Wheel Assembly................9 Hinge the Rudder....................................10 Install the Tail Wheel..............................11 Hinge the Bottom Wing Ailerons............11 Hinge the Top Wing Ailerons..................11 Engine Mounting...........................................12 Mounting Engine to Motor Mount...........12 Aligning the Motor Mount.......................12 Mounting the Engine to Firewall..............13 Fuel Tank......................................................13 Fuel Tank Assembly................................13 Fuel Tank Installation..............................14 Throttle Linkage............................................14 Installing the Throttle Linkage.................14 Main Landing Gear........................................14 Installing the Gear Bracket.......................14 Installing the Wheel Pants........................15 Adjusting the Wheel Pants.......................15 Aileron Servo................................................16 Installing the Aileron Servo.....................16 Installing the Aileron Linkage..................16 Radio Installation...........................................17 Installing the Servo Tray..........................17 Installing the Servos.................................17 Installing the Receiver and Battery...........17 Installing the Switch................................17 Throttle Linkage............................................18 Installing the Throttle Connector..............18 Rudder Pushrod..............................................18 Installing the Rudder Control Horn..........18 Installing the Rudder Pushrod..................19 Elevator Pushrod............................................20 Installing the Elevator Control Horns.......20 Installing the Pushrod Joiner....................20 Installing the Elevator Pushrod.................20 Aileron Links.................................................21 Installing the Control Horns.....................21 Installing the Aileron Links......................22 Canopy..........................................................22 Trimming the Canopy..............................22 Mounting the Canopy..............................22 Cowling.........................................................22 Mounting the Cowl..................................22 Balancing.......................................................24 Lateral Balance........................................24 Control Throws..............................................24 Flying............................................................25 Notes.............................................................25 Trim Chart.....................................................26 Global guarantees this kit to be free from defects in both material and workmanship, at the date of purchase. This does not cover any components parts damaged by use, misuse or modification. In no case shall Global's liability exceed the original cost of the purchased kit. In that Global has no control over the final assembly or material used for final assembly, no liability shall be assumed for any damage resulting from the use by the user of the final user-assembled product. By the act of using the final user-assembled product, the user accepts all resulting liability. To make your modeling experience totally enjoyable, we recommend that you get experienced, knowledgable help with assembly and during your first flights. Your local hobby shop has information about flying clubs in your area whose membership includes qualified instructors. You can also contact the AMA at the address below. Academy of Model Aeronautics 5151 East Memorial Drive Muncie, IN. 47302-9252 (800) 435-9262 www.modelaircraft.org 2 This instruction manual is designed to help you build a straight, great flying airplane. Please read this manual thoroughly before beginning assembly of your new Ultimate Biplane. Use the parts listing below to identify and separate all parts before beginning assembly. ** KIT CONTENTS** We have organized the parts as they come out of the box for better identification during assembly. We recommend you regroup the parts in the same manner. This will ensure you have all of the parts required before you begin assembly and will also help you familiarize yourself with each part. KIT CONTENTS AIRFRAME ASSEMBLIES RUDDER CONTROL SYSTEM o {1} Fuselage w/Metal Cabane Struts, Pushrod Housings, Wood Gear Cover (D-29), and Horizontal Stabilizer Spacer (D-26A) o {1} Bottom Wing w/Ailerons & Hinges o {1} Top Wing w/Ailerons & Hinges o {1} Vertical Stabilizer w/Rudder & Hinges o {1} Horizontal Stabilizer w/Elevator Halves & Hinges o {2} Outboard Interplane Struts o {1} Fiberglass Cowling o {1} Clear Canopy o o o o o o o {1} {2} {2} {3} {2} {4} {2} {2} {2} {4} o o o o o o o Prebent Aluminum Landing Gear Wheel Pants 60mm Diameter Wheels 4mm x12mm Machine Screws 4mm x 35mm Axle Screws 2mm x 8mm Wood Screws 4mm Flat Washers 4mm Hex Nuts 4mm Lock Nuts 4mm Nylon Spacers o {1} Tail Wheel Wire w/Nylon Bearing o {1} 25mm Diameter Tail Wheel o {1} Wheel Collar w/3mm x 6mm Machine Screw ELEVATOR CONTROL SYSTEM {2} {4} {2} {2} {3} {1} {2} {4} {1} {1} Nylon Control Horns w/Nylon Back Plates 2mm x 15mm Machine Screws 600mm Nylon Pushrods 2mm x 100mm Wire Threaded Both Ends Nylon Clevises (one w/1.5mm I.D. Hole) Nylon Joiner Plate 2.2mm x 10mm Wood Screws 2mm Flat Washers 2mm x 20mm Machine Screw 2mm Hex Nut Nylon Control Horns w/Nylon Back Plates 2mm x 15mm Machine Screws 2mm x 200mm Wire Threaded w/L-Bend 2mm x 85mm Wire Threaded w/L-Bend Nylon Clevises Nylon Snap Keepers Nylon Adjustable Control Horns o o o o o o o o {1} {1} {1} {1} {1} {1} {3} {1} Molded Fuel Tank Rubber Stopper 20mm Diameter Front Squash Plate 18mm Diameter Rear Squash Plate 3mm x 20mm Machine Screw Weighted Metal Pick-Up Aluminum Tubes 90mm Silicon Fuel Tube o o o o o o o o o {4} {8} {4} {2} {2} {2} {1} {1} {2} 3mm x 16mm Machine 3mm Flat Washers 3mm Blind Nuts 4mm x 25mm Machine 4mm Flat Washers 4mm Blind Nuts 3mm x 50mm Machine 3mm x 35mm Machine 3mm Lock Nuts o o o o o o o o o {1} {2} {1} {2} {1} {2} {4} {4} {1} Wing Bolt Doubler (W-24) Wing Servo Mounting Plate (W-25) Wing Cabane Shim (D-31) Pushrod Supports (D-32) Fuselage Servo Tray (D-15) Balsa Support Rails (D-30) 2mm x 10mm Wood Screws 3mm x 6mm Wood Screws 35mm Clevis Retaining Tube WING MOUNTING MOTOR MOUNT ASSEMBLY o o o o o {4} {8} {2} {2} {4} {4} {2} FUEL TANK ASSEMBLY TAIL WHEEL ASSEMBLY o o o o o o o o o o Nylon Control Horn w/Nylon Back Plate 2mm x 15mm Machine Screws 700mm Nylon Pushrod 2mm x 120mm Wire Threaded Both Ends 2mm x 85mm Wire Threaded w/L-Bend Nylon Snap Keeper Nylon Clevis AILERON CONTROL SYSTEM MAIN GEAR ASSEMBLY o o o o o o o o o o {1} {2} {1} {1} {1} {1} {1} Screws Screws Screw Screw MISCELLANEOUS {2} Nylon Mounting Beams {4} 3mm x 20mm Machine Screws {4} 3mm x 25mm Machine Screws {16}3mm Flat Washers {8} 3mm Lock Nuts THROTTLE CONTROL SYSTEM o {1} 1.5mm x 300mm Wire Threaded One End o {1} Nylon Clevis w/1.5mm I.D. Hole o {1} Adjustable Servo Connector Assembly 3 ADDITIONAL ITEMS REQUIRED o o o o o o o o {1}Hitec 4 Channel Radio w/4 Servos {1}Dubro Foam Rubber # 513 {1}Global Fuel Line # 115923 {1}Dubro Fuel Filler Valve # 334 {1}Goldberg 1/4” White Striping Tape # 724 {1}Goldberg 1/8” Black Striping Tape # 711 {1}Coverite 21st Century Red Paint # COVR0102 {1}Coverite 21st Century Clear # COVR1265 FOR 4-STROKE ENGINE o o o o {1}Magnum XL .52-.80 Four Stroke {1}Magnum 2-1/2” Aluminum Spinner # 237154 {1}Propeller To Suit Engine {1}Thunderbolt Glow Plug # 115490 FOR 2-STROKE ENGINE o o o o o OPTIONAL ITEMS o {1}Williams Bros. 2-5/8” Pilot # 18500 o {1}Ernst External Charge Jack # 124 o {1}Cirrus On-Board Battery Indicator # 444762 {1}Magnum XL .46-.53 Two Stroke {1}Pitts Style Muffler to Suite Engine {1}Magnum 2-1/2” Aluminum Spinner # 237154 {1}Propeller To Suit Engine {1}Thunderbolt Glow Plug # 115493 TOOLS AND SUPPLIES NEEDED o o o o o o o o o o o o o o o o o o o o o o o o o Kwik Bond Thin C/A # 887500 Kwik Bond Thick C/A # 887510 Kwik Bond 5 Minute Epoxy # 887560 Kwik Bond 30 Minute Epoxy # 887565 Pacer Canopy Glue # PT-56 Pacer Thread Lock # PT-42 Silicon Sealer Electric Drill Assorted Drill Bits Modeling Knife Machine Oil or Vaseline Rubbing Alcohol Paper Towels Straight Edge Ruler Dremel Tool w/Assorted Bits Robart Incidence Meter # 404 Ernst Airplane Stand # 157 Phillips Screwdriver Flat Blade Screwdriver Wire Cutters Pliers Builders Triangle 220 Grit Sandpaper Masking Tape Scissors FIELD SUPPORT EQUIPMENT NEEDED o o o o o o o o Magnum 12V Electric Starter (# 361006) Magnum 12V Fuel Pump (# 237377) Magnum Locking Glow Clip (# 237440) Global 12V Battery (# 110171 ) Global 12V Charger (# 110270 ) Magnum Power Panel (# 237390) Global Field Buddy Flight Box (# 233072) Magnum 4-Way Wrench (# 237420) METRIC CONVERSION CHART To convert inches into millimeters: Inches x 25.4 = MM 1/64” 1/32” 1/16” 3/32” 1/8” 5/32” = = = = = = .4mm .8mm 1.6mm 2.4mm 3.2mm 4.0mm 3/16” 1/4” 3/8” 1/2” 5/8” 3/4” = = = = = = 4.8mm 6.4mm 9.5mm 12.7mm 15.9mm 19.0mm 1” 2” 3” 6” 12” 18” 4 = = = = = = 25.4mm 50.8mm 76.2mm 152.4mm 304.8mm 457.2mm 21” 24” 30” 36” = = = = 533.4mm 609.6mm 762.0mm 914.4mm If you should find a part missing or have questions about assembly, please call or write to the address below: Customer Service Center 18480 Bandilier Circle Fountain Valley, CA. 92728 Phone: (714) 963-0329 Fax: (714) 964-6236 E-Mail: globalhobby@earthlink.net **SUGGESTION** To avoid scratching or damaging your new airplane, do not unwrap the pieces until they are needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after you open the bags. **NOTE** Please trial fit all the parts. Make sure that you have the correct parts and that they fit and are aligned properly before gluing! This will ensure proper assembly. Since the Ultimate Biplane is hand made from natural materials, every plane is unique and minor adjustments may have to be made. However, you should find the fit superior and assembly simple. o 3) With the wing in the wing saddle, align the two marks and hold the wing securely in place using a couple of pieces of masking tape. BOTTOM WING MOUNTING o o o o o {1} {1} {2} {2} {2} PARTS REQUIRED Bottom Wing w/Ailerons & Hinges Wing Bolt Doubler (W-24) 4mm x 25mm Machine Screws 4mm Washers 4mm Blind Nuts o 4) Remove the ailerons from the wing. To double check that the wing is square to the fuselage, use a ruler and measure from each wing tip to the rear edge of the fuselage. Both measurements should be equal. See figure # 1 below. ALIGN THE BOTTOM WING o 1) Place the wing into the wing saddle making sure that the preinstalled dowel in the leading edge of the wing fully engages the predrilled hole in the forward bulkhead in the fuselage. Push the wing as far forward as possible. The leading edge should fit tight against the bulkhead. Figure # 1 A o 2) Using a ruler and pen, measure and place a mark on the centerline of the bottom of the fuselage at the rear of the wing saddle. Also measure and place a mark at the centerline of the wing at the trailing edge. See photo # 1 below. A1 A=A1 INSTALLING THE BLIND NUTS o 5) When satisfied with the alignment, use a 5/32” drill bit and drill two holes through the wing and on through the plywood wing hold down block. The holes are located 1-1/2” out from the centerline and 1/2” forward of the trailing edge. Photo # 1 DRAW CENTERLINE DRAW CENTERLINE 5 o 6) Remove the wing from the wing saddle. Drill out only the holes in the plywood wing mounting block using a 7/32” drill bit. o 11) Mix up a small amount of Kwik Bond 5 Minute Epoxy and use it to glue the wing doubler to the wing. Allow the epoxy to fully cure. Drilling out only these holes will allow easier installation of the blind nuts in the next step. o 12) Remove the wing and drill out the holes through the doubler using a 5/32” drill bit. Use the holes already drilled through the wing as a guide and drill down through the top of the wing. o 7) Install the two 4mm blind nuts from underneath the plywood wing hold down block. The blind nuts can be installed using pliers by first removing the portion of the balsa filler block directly above where the blind nuts are installed. See photo # 2 below. INSTALLING THE WING o 13) Place the wing back into the wing saddle. Secure the wing in place using the two 4mm x 25mm machine screws and two 4mm washers. See photo # 3 below. Photo # 3 Photo # 2 REMOVE BALSA WING BOLT DOUBLER INSERT BLIND NUT FROM BOTTOM HORIZONTAL STABILIZER MOUNTING INSTALLING THE WING BOLT DOUBLER o 8) Place the wing back into the wing saddle, aligning the centerline marks. While holding the wing firmly in place, set the wing bolt doubler (W-24) in place. The rear edge of the doubler should be just forward of the rear edge of the wing saddle and the sides of the doubler should be flush with the sides of the fuselage. PARTS REQUIRED o {1} Horizontal Stabilizer w/Elevator Halves and Hinges ALIGN THE HORIZONTAL STABILIZER o 1) Using a modeling knife, carefully remove the covering from over the stabilizer slot precut in the rear of the fuselage. The slot is located about 3” up from the bottom of the fuselage. There is a precovered wood spacer at the end of the slot. It is not glued in and should be removed and saved. See photo # 4 below. o 9) While holding the doubler in place, use a pen and draw around the doubler to outline it onto the wing surface. Photo # 4 o 10) Remove the doubler and using a modeling knife, carefully remove the covering from just inside the outline. REMOVE COVERING REMOVE BALSA BLOCK 6 o 2) Remove the elevator halves from the stabilizer. Using a ruler and pen, locate and mark the centerline of the horizontal stabilizer at the trailing edge and place a mark. Use a triangle and extend this mark, from back to front, across the top and bottom of the stabilizer. MOUNTINGTHEHORIZONTALSTABILIZER o 6) With the stabilizer held firmly in place, use a pen and draw a line where it and the fuselage sides meet. Do this on both the right and left sides and top and bottom of the stabilizer. o 7) Remove the stabilizer. Using the lines you just drew as a guide, carefully remove the covering from between them, using a modeling knife. See photo # 5 below. o 3) Slide the stabilizer into the slot. The stabilizer should be pushed firmly up against the front of the slot, leaving about 1-1/2” of space between the trailing edge and the rear of the fuselage. Photo # 5 o 4) With the wing still attached to the fuselage, align the centerline mark on top of the stabilizer with the centerline of the fuselage at the rear. When that is aligned hold the stabilizer in that position using a T-pin and align the horizontal stabilizer with the wing. When viewed from the rear, the horizontal stabilizer should be level with the wing. If it is not level, use sandpaper and sand down the high side of the stabilizer mounting platform until the proper alignment is achieved. The tips of the stabilizer should also be equal distance from the tips of the wing. See figures # 2 and # 3 below. REMOVE COVERING When cutting through the covering to remove it, cut with only enough pressure to only cut through the covering itself. Cutting into the balsa structure may weaken it. o 8) When you are sure that everything is aligned correctly, mix up a generous amount of Kwik Bond 30 Minute Epoxy. Apply a thin layer to the top and bottom of the stabilizer mounting area and to the stabilizer mounting platform on the fuselage. Set the stabilizer in place and realign. Double check all of your measurements once more before the epoxy cures. Hold the stabilizer in place with T-pins or masking tape and remove any excess epoxy using paper towels and rubbing alcohol. Figure # 2 A A1 Figure # 3 B o 9) After the epoxy has fully cured, install the precovered spacer that you removed earlier back into the slot . Glue the spacer in place using Kwik Bond Thick C/A. See photo # 6 below. B1 Photo # 6 o 5) When you are satisfied with the alignment, hold the stabilizer in place with T- pins or masking tape, but do not glue at this time. 7 REINSTALL WOOD BLOCK MOUNTING THE VERTICAL STABILIZER VERTICAL STABILIZER MOUNTING o 6) When you are sure that everything is aligned correctly, mix up a generous amount of Kwik Bond 30 Minute Epoxy. Apply a thin layer to the mounting slot in the top of the fuselage and to the sides and bottom of the vertical stabilizer mounting area. Set the stabilizer in place and realign. Double check all of your measurements once more before the epoxy cures. Hold the stabilizer in place with T-pins or masking tape and remove any excess epoxy using paper towels and rubbing alcohol. Allow the epoxy to fully cure before proceeding. PARTS REQUIRED o {1} Vertical Stabilizer w/Rudder and Hinges ALIGN THE VERTICAL STABILIZER o 1) Using a modeling knife, carefully remove the covering from over the stabilizer slot precut in the top rear of the fuselage. o 2) Remove the rudder from the stabilizer. Slide the stabilizer into the slot in the top of the fuselage. The rear edge of the stabilizer should be even with the rear edge of the fuselage and it should be firmly pushed down completely into the slot. TOP WING MOUNTING o 3) Using a pen, draw a line on each side of the vertical stabilizer where it meets the top of the fuselage. o o o o o o o o o 4) Remove the stabilizer. Using a modeling knife, remove the covering from below the lines you drew. Also remove the covering from the bottom edge of the stabilizer. See photo # 7 below. {1} {1} {2} {4} {8} {4} {1} {1} PARTS REQUIRED Top Wing w/Ailerons & Hinges Wing Cabane Shim (D-31) Outboard Interplane Struts 3mm x 16mm Machine Screws 3mm Flat Washers 3mm Blind Nuts 3mm x 50mm Machine Screw 3mm x 35mm Machine Screw ALIGN THE TOP WING Set-up is extremely important in any airplane. However, wing incidence is critical in a biplane to achieve proper flight performance. Incidence is the angle the flying surfaces flow through the air. The Ultimate should be set with the stabilizer at 0º, the lower wing at 0º, and the top wing at 0º or -1º incidence. The following installation procedures explain how to achieve proper initial setup. See figure # 5 below. Photo # 7 REMOVE COVERING When cutting through the covering to remove it, cut with only enough pressure to only cut through the covering itself. Cutting into the balsa structure may weaken it. Figure # 5 0º or -1º o 5) Set the vertical stabilizer back in place. Using a triangle, check to ensure that the vertical stabilizer is aligned 90º to the horizontal stabilizer. See figure # 4 below. 0º 0º Figure # 4 o 1) With the bottom wing installed, set the airplane upright in an airplane stand. 90º We highly recommend using a stand. They can be purchased separately or made yourself using items found around your shop. 8 o 6) Locate and remove the covering from over the two predrilled wing hold down holes in the top wing. These holes are located down the centerline of the wing. The forward hole is located 7” in front of the trailing edge and the rear hole is located 3-5/8” in front of the trailing edge. Remove the covering from both the top and bottom of the holes. o 2) With the airplane setting in the stand, attach an incidence meter to the horizontal stabilizer. Adjust the airplane in the stand until the incidence meter reads 0º. See photo # 8 below. Photo # 8 o 7) Mount the top wing to the aluminum cabane struts using the 3mm x 50mm machine screw in the front, the 3mm x 35mm machine screw in the rear. Use four 3mm washers and two 3mm lock nuts to secure the wing in place. o 3) Use rubber bands or weights to hold the airplane in position in the stand. It needs to be secured so it cannot be moved during the next few steps. After you are satisfied it has been secured properly, recheck the stabilizer incidence to ensure it is still at 0º. If the holes in the wing do not align with the holes in the cabane struts loosen the strut screws further to allow the metal parts to adjust to the wing. The screws will be completely tightened after the wing alignment has been set. See photo # 10 below. Photo # 10 o 4) Remove the incidence meter from the stabilizer and attach it to the bottom wing. The incidence meter should read 0º as well. If the incidence meter does not read 0º then recheck the incidence of the stabilizer to ensure it has not moved. If you are certain it hasn't, recheck the incidence of the bottom wing. You should make small adjustments to the wing saddle until the incidence meter reads 0º on the bottom wing. SCREWS INSTALLING THE INTERPLANE STRUTS o 8) Locate the two outer interplane struts. There is a top and bottom to the struts. There are two predrilled holes in one end of each strut. Where these two holes are located is the bottom of the strut. Using a modeling knife, remove the covering from over these holes on both sides of each strut. See figure # 6 below. o 5) Working with the top wing, first identify the bottom surface of it. If you look closely, two ribs in from each tip, there is a precut slot that is 2” long and accepts the outer interplane struts. This is the bottom of the wing. Using a modeling knife, remove the covering from over these two slots. See photo # 9 below. Photo # 9 Figure # 6 APPROXIMATE HOLE LOCATIONS FRONT BOTTOM OF STRUT o 9) On the top side of the bottom wing there are two slots for the struts similar to those in the top wing . These two slots are located just to the outside of the strut mounting blocks in the top side of the bottom wing. Using a modeling knife, remove the covering from over the two slots. REMOVE COVERING 9 o 10) There are two predrilled holes through each strut mounting block in the bottom wing. Using a modeling knife, remove the covering from over these holes. o 16) When completely satisfied with the alignment of the top wing use threadlock on all of the metal cabane screws and nuts and tighten them completely to lock the wing's alignment in place. o 11) Install one 4mm blind nut in each of the four holes in the strut mounting blocks. The blind nuts should be mounted on the inside edge of the blocks. See photo # 11 below. o 17) Using a pen draw a line on each side of the outer interplane struts where they meet the bottom surface of the top wing. o 18) Remove the top wing and outer interplane struts. Using a modeling knife, remove the covering from the interplane struts from just inside the lines you drew on them. Photo # 11 P TI o 19) Mix up a generous amount of Kwik Bond 30 Minute Epoxy. Glue the outer interplane struts into the TOP WING ONLY. Before the epoxy cures, reinstall the top wing and secure the interplane struts into the bottom wing with the four machine screws. Allow the epoxy to fully cure before proceeding. See photo # 12 below. BLIND NUTS o 12) Remove the top wing. Plug the two interplane struts into the corresponding slots in the bottom of the top wing. The predrilled holes in the struts should be on the bottom and the edge of the struts covered in red should face the leading edge of the wing. Photo # 12 o 13) Reinstall the top wing making sure the two outer interplane struts completely engage the two slots in the top side of the bottom wing. o 14) Secure the outer interplane struts in place using the four 3mm x 16mm machine screws and four 3mm flat washers. The machine screws pass through the strut and thread into the blind nuts installed in the mounting blocks. BOTTOM WING TOP WING CONTROL SURFACE INSTALLATION MOUNTING THE TOP WING o o o o o o o o 15) Remove the ailerons from the top wing. Attach the incidence meter to the top wing and check the incidence. The meter should read either 0º or -1º. If the incidence meter does not read 0º or -1º then you may need to adjust the metal cabane struts and /or shim the space between the rear metal cabane strut and the wing. We have provided a hardwood cabane shim (D-31) for this purpose. {2} {2} {2} {1} {1} {1} {1} PARTS REQUIRED Top Wing Ailerons w/Hinges Bottom Wing Ailerons w/Hinges Elevator Halves Rudder Tail Wheel Wire w/Nylon Bearing 25mm Diameter Tail Wheel Wheel Collar w/3mm x 6mm Machine Screw HINGE THE ELEVATOR HALVES o 1) The C/A hinges have already been glued into the two elevator halves. Working with one half at a time, slide the elevator and it's hinges into their precut hinge slots in the trailing edge of the horizontal stabilizer. Slide 1 0 o 7) Mix up a small amount of Kwik Bond 5 Minute Epoxy. Apply the epoxy to only those parts of the tail wheel wire that will be glued to the rudder, being careful not to get any epoxy on the nylon bearing. Pack epoxy into the hole you drilled in the leading edge of the rudder also. the elevator in until it is tight against the trailing edge of the stabilizer. The maximum hinge gap should be no more than 1/32”, but there should be about a 1/16” gap between the counterbalance section of the elevator and the tip of the stabilizer. See photo # 13 below. Photo # 13 o 8) Insert the tail wheel wire into the rudder. Clean up any excess epoxy using a paper towel and rubbing alcohol. See photo # 14 below. STABILIZER Photo # 14 1/32” ELEVATOR EPOXY TAIL WHEEL WIRE o 2) With the elevator tight against the stabilizer, rotate the elevator down about 45º. Apply six drops of Kwik Bond Thin C/A to the exposed area of each hinge. Allow the glue to cure for about ten minutes. Once cured, the elevator may be stiff and difficult to move. This is normal. Gently move the elevator up and down about five to ten times to free it up. EPOXY NYLON BEARING HINGE THE RUDDER o 9) Using a modeling knife, remove the covering from over the lower hinge slot and nylon bearing slot precut in the back edge of the fuselage. Use the rudder to help locate the slots. o 3) Repeat steps # 1 and # 2 for the second elevator half. INSTALL THE TAIL WHEEL ASSEMBLY o 10) The C/A hinges have already been glued into the rudder. Slide the rudder and it's hinges, including the nylon bearing tab into their precut hinge slots in the trailing edge of the vertical stabilizer and lower section of the fuselage. Slide the rudder in until it is tight against the trailing edge of the stabilizer. The maximum hinge gap should be no more than 1/32”. See photo # 15 below. o 4) Using a ruler, measure up from the bottom of the rudder at the leading edge 1-1/8” and place a mark. o 5) Using a 5/64” drill bit, drill a hole into the rudder at the mark made. Using a modeling knife, cut a groove from the hole down to the bottom of the rudder. Make the hole deep enough for the tail wheel wire and the nylon bearing to set flush in. See figure # 7 below. Photo # 15 Figure # 7 NYLON BEARING DRILL HOLE CUT GROOVE 1/32” o 6) Apply oil or Vaseline to the hinge bearing to prevent epoxy from gluing the bearing solid to the tail wheel wire. TAIL WHEEL WIRE 1 1 o 11) Mix up a small amount of Kwik Bond 30 Minute Epoxy. Remove the rudder and apply a thin layer of epoxy to only the tab on the nylon bearing. Be careful not to get any epoxy on the tail wheel wire. The waxed paper will prevent epoxy from gluing the torque rod to the trailing edge of the wing. o 16) Mix up a small amount of Kwik Bond 30 Minute Epoxy. Apply a thin layer of epoxy to the aileron torque rod. Also use a toothpick and pack epoxy into the predrilled hole in the aileron. o 12) Slide the rudder and it's hinges, including the nylon bearing tab into their precut hinge slots in the trailing edge of the vertical stabilizer and lower section of the fuselage. With the rudder tight against the stabilizer, rotate the rudder to one side about 45º. Apply six drops of Kwik Bond Thin C/A to the exposed area of each hinge. Allow the glue to cure for about ten minutes. Once cured, the rudder may be stiff and difficult to move. This is normal. Gently move the rudder back and forth about five to ten times to free it up. o 17) Slide the aileron and it's hinges into their precut hinge slots in the trailing edge of the wing, making sure the torque rod is firmly seated in the precut hole in the leading edge of the aileron. With the aileron tight against the wing, rotate the aileron down about 45º. Apply six drops of Kwik Bond Thin C/A to the exposed area of each hinge. Allow the glue to cure for about ten minutes. Once cured, the aileron may be stiff and difficult to move. This is normal. Gently move the aileron up and down about five to ten times to free it up. INSTALL THE TAIL WHEEL o 13) Install the 25mm diameter tail wheel on the tail wheel wire. Secure the tail wheel in place using one wheel collar and 3mm x 6mm machine screw. The tail wheel should turn without binding. o 18) Repeat steps # 14 - # 17 for the second aileron. HINGE THE BOTTOM WING AILERONS o 14) The C/A hinges have already been glued into the two ailerons. Working with one aileron at a time, slide the aileron and it's hinges into their precut hinge slots in the trailing edge of the wing, making sure the torque rod is firmly seated in the precut hole in the leading edge of the aileron. Slide the aileron in until it is tight against the trailing edge of the wing. The maximum hinge gap should be no more than 1/32” and the tip of the aileron should be flush with the tip of the wing. HINGE THE TOP WING AILERONS o 19) The C/A hinges have already been glued into the two ailerons. Working with one aileron at a time, slide the aileron and it's hinges into their precut hinge slots in the trailing edge of the wing. Slide the aileron in until it is tight against the trailing edge of the wing. The maximum hinge gap should be no more than 1/32” and the tip of the aileron should be flush with the tip of the wing. o 20) With the aileron tight against the wing, rotate the aileron down about 45º. Apply six drops of Kwik Bond Thin C/A to the exposed area of each hinge. Allow the glue to cure for about ten minutes. Once cured, the aileron may be stiff and difficult to move. This is normal. Gently move the aileron up and down about five to ten times to free it up. o 15) When satisfied with the fit, remove the aileron and slide a small piece of waxed paper between the aileron torque rod and the trailing edge of the wing. See photo # 16 below. Photo # 16 WAXED PAPER o 21) Repeat steps # 19 and # 20 for the opposite aileron. TORQUE ROD 1 2 ALIGNING THE MOTOR MOUNT ENGINE MOUNTING o o o o o o 5) The engine is mounted sideways on the firewall. Using a ruler and pen, measure and draw a vertical centerline on the firewall. PARTS REQUIRED {2} Nylon Mounting Beams {4} 3mm x 20mm Machine Screws {4} 3mm x 25mm Machine Screws {16}3mm Flat Washers {8} 3mm Lock Nuts o 6) Measure down from the top of the fuselage 1-1/2” and draw a horizontal line on the firewall. See photo # 18 below. MOUNTING ENGINE TO MOTOR MOUNT Photo # 18 o 1) Using a clamp or a vise, align the two motor mount beams and clamp them together. The beam halves are universal and the webbing should face the outside edges. See photo # 17 below. 1-1/2” 1-1/2” Photo # 17 o 7) With your engine still installed on the motor mount beams, use a ruler and measure the width between the predrilled mounting holes in the motor mount. This distance will vary depending on the brand and size of the engine you have chosen. See photo # 19 below. o 2) Mark the locations of the four engine mounting holes on the beams using a pencil. For the engine to align properly with the front of the cowling, it is important that the front edge of the engine's drive washer be 4-7/8” forward from the rear edge of the mounting beams. Photo # 19 MOUNTING BEAM MOUNTING BEAM D = Distance Between Predrilled Holes In Beams (Will Vary Depending Engine Used) o 3) When satisfied with the alignment of the engine, remove the beams from the clamp and drill 1/8” holes through the mounting beams at the four engine mounting hole locations. o 8) Divide the measurement found in step # 7 in half. Measure this resulting distance and draw one horizontal line above and below the horizontal centerline. o 4) Mount the engine to the mounting beams using the four 3mm x 25mm machine screws, eight 3mm flat washers, four 3mm lock nuts. Tighten the screws and nuts completely. o 9) On the two horizontal lines you just drew, measure and place marks 3/8” to the left and 1-1/4” to the right of the vertical centerline (looking at the firewall). See photo # 20 below. Photo # 20 If using an engine equipped with a remote needle valve we recommend mounting the needle valve to the engine prior to installing the engine on the motor mount beams. 1 3 D o 10) Hold the motor mount assembly up to the firewall and double check that the four intersecting lines line up with the four predrilled holes in the motor mount. o 2) Using 220 grit sandpaper carefully smooth each end of the two tubes. This will prevent the fuel line from being cut. o 3) Push the two aluminum tubes through the rubber stopper until 1/2” protrudes from the front of the stopper. Slide the 20mm diameter front squash plate over the tubes at the front of the stopper and slide the 18mm diameter rear squash plate over the tubes at the rear of the stopper. Insert the 3mm x 20mm machine screw into the center hole in the front squash plate, then screw it through the stopper and into the rear squash plate. Do not completely tighten the screw at this time. The motor mount is offset to the airplane's left side (looking from the rear) to compensate for the right thrust built into the firewall. Offsetting the engine will allow the spinner to line up with cowl ring when it is installed later. MOUNTING THE ENGINE TO FIREWALL o 11) Using a 1/8” drill bit, drill the mounting holes through the firewall for the motor mount. o 12) Mount the motor mount assembly to the firewall using the four 3mm x 20mm machine screws, eight 3mm flat washers and four 3mm lock nuts. Tighten the screws and nuts completely. See photo # 21 below. o 4) Carefully bend the longer of the two tubes up at a 45º angle. This tube is the vent tube. When the stopper assembly is installed in the tank, the top of the vent tube should rest just inside the bubble in the top of the tank. Photo # 21 o 5) Slide the silicon fuel tubing, with the weighted pickup attached to one end, onto the fuel pickup tube. See photo # 22 below. Photo # 22 RUBBER STOPPER VENT TUBE FUEL TANK o o o o o o o o {1} {1} {1} {1} {1} {1} {3} {1} FRONT SQUASH PLATE PARTS REQUIRED Molded Fuel Tank Rubber Stopper 20mm Diameter Front Squash Plate 18mm Diameter Rear Squash Plate 3mm x 20mm Machine Screw Weighted Metal Pick-Up Aluminum Tubes 90mm Silicon Fuel Tube REAR SQUASH PLATE FUEL TUBING PICK-UP o 6) Test fit the stopper assembly into the tank. It may be necessary to remove some of the flashing around the tank opening using a modeling knife. If flashing is present, make sure none falls into the tank. FUEL TANK ASSEMBLY o 7) With the stopper assembly in place the weighted pickup should be about 3/8” away from the rear of the tank and move freely inside the tank. The vent tube should be inside the bubble in the tank, but not rub against the tank. Adjust the tubes accordingly. o 1) The fuel tank assembly incudes 3 different length aluminum tubes. Discard the shortest of the three. It will not be used. The 50mm length tube is used for the fuel line pickup and the 80mm tube is used for the vent/pressure line. 1 4 o 8) When satisfied with the alignment of the stopper assembly tighten the 3mm x 20mm machine screw until the rubber stopper expands and seals the tank opening. Do not overtighten the assembly as this could cause the tank to split. (FOUR STROKE SET UP) Photo # 23 Enlarge hole in firewall to allow clevis to pass through. NYLON CLEVIS PUSHROD WIRE FUEL TANK INSTALLATION o 9) Slide the fuel tank into the fuel tank compartment in the front of the airplane. The bubble in the tank should face the top of the fuselage and the tank should rest on the balsa fuel tank support floor. The stopper assembly should also engage the predrilled hole in the firewall. THROTTLE ARM THROTTLE ARM Photo # 24 PUSHROD WIRE NYLON CLEVIS o 10) Secure the fuel tank in place using foam rubber. Seal any gaps between the stopper assembly and the firewall using silicon sealer. Be careful not to get any sealer inside the aluminum tubing. (TWO STROKE SET UP) MAIN LANDING GEAR THROTTLE LINKAGE o o o o o o o o o o o PARTS REQUIRED o {1} 1.5mm x 300mm Wire Threaded One End o {1} Nylon Clevis w/1.5mm I.D. Hole INSTALLING THE THROTTLE LINKAGE o 1) Thread the nylon clevis onto the threaded end of the 300mm pushrod wire. This clevis has a 1.5mm I.D. hole that matches the diameter of the pushrod wire. All other clevises in the kit use a larger diameter hole for larger wire. {1} {1} {2} {2} {3} {2} {4} {2} {2} {2} {4} PARTS REQUIRED Prebent Aluminum Landing Gear Wood Gear Cover (D-29) Wheel Pants 60mm Diameter Wheels 4mm x12mm Machine Screws 4mm x 35mm Axle Screws 2mm x 8mm Wood Screws 4mm Flat Washers 4mm Hex Nuts 4mm Lock Nuts 4mm Nylon Spacers INSTALLING THE GEAR BRACKET o 1) Install the prebent aluminum gear bracket using the three 4mm x 12mm machine screws. The gear bracket fits into the gear slot just ahead of the bottom wing opening. Three 4mm blind nuts have been preinstalled. Tighten the screws completely. See photo # 25 below. o 2) Locate and drill a 3/32” hole through the firewall for the throttle pushrod wire to pass through. The hole should be level with the throttle arm, but moved over enough to clear the fuel tank. Be careful not to drill into the fuel tank. Photo # 25 GEAR BRACKET o 3) Slide the pushrod wire through the hole and into the fuselage. Attach the clevis to the throttle arm. Use a pair of pliers and make the necessary bends in the wire so it does not bind when moved from idle to the full throttle position. See photos # 23 & # 24 at top right. MOUNTING SCREWS 1 5 o 2) Mix up a small amount of Kwik Bond 5 Minute Epoxy. Use a couple of small dabs of epoxy to glue the balsa gear cover (D-29) onto the aluminum gear, flush with the bottom of the fuselage. o 5) Slide two 4mm nylon spacers over the axle screw and up against the wheel. Thread one 4mm hex nut onto the axle screw. o 6) Tighten the hex nut against the nylon spacers as tight as it can be, but still allow the wheel to spin free on the axle. Secure the nut in place by carefully applying a couple of drops of Kwik Bond Thick C/A to the threads. Allow the C/A to fully cure. See photo # 27 below. There are three holes predrilled through the block that allow the screws to be removed should the gear need servicing. You can leave these holes covered by the covering or remove the covering from over them now using a modeling knife. Photo # 27 INSTALLING THE WHEEL PANTS o 1) Working with one wheel pant at a time, use a Dremel Tool and remove the plastic that covers the wheel opening on the bottom of the wheel pant. NYLON SPACERS Look carefully at each side of the wheel pant and you will notice a molded dimple. One dimple is about 1/8” higher on one side than the other. If you will be flying off a hard surface we recommend you drill out the dimple that is higher. If flying off of grass we recommend you drill out the dimple that is lower. This will raise the wheel pant higher on the axle and give more clearance between the wheel pant and the ground. HEX NUT o 7) Slide one 4mm washer over the axle screw and up against the hex nut. Carefully slip the wheel and axle assembly into the wheel pant. The axle screw should slip firmly into the slot in the wheel pant and the flat washer should be positioned inside the wheel pant. o 8) Slide the axle bolt through the predrilled 4mm hole in the aluminum gear bracket and secure in place using one 4mm lock nut. Tighten the lock nut completely, at the same time making sure the hex nut does not come loose. Double check that the wheel does not bind when rotated. o 2) Using a 5/32” drill bit, drill out only the one dimple that you choose. o 3) Using a modeling knife, cut a slot from the hole down to the wheel pant opening. See photo # 26 below. Photo # 26 AXLE SCREW o 9) Repeat steps # 1 - # 8 for the opposite side. CUT SLOT ADJUSTING THE WHEEL PANTS o 10) With both wheels and wheel pants installed on the gear bracket, set the airplane on it's wheels on a level surface. Adjust the wheel pants so the rear portion of the wheel pant is level with the ground. Double check that both wheel pants are level with each other. REMOVE COVER o 4) Slide one 60mm diameter wheel onto one 4mm x 35mm axle screw. The wheel should go on with flat side of the hub first. 1 6 o 11) When satisfied with the alignment, secure the wheel pants in place by installing two 2mm x 8mm wood screws through the two predrilled holes in the gear bracket and into the side of the wheel pant. Do this for both wheel pants. See photo # 28 below. o 3) Hold the two plates in place and trace around them using a pen. Remove the plates and using a modeling knife, remove the covering from just inside the lines. o 4) Mix a small amount of Kwik Bond 5 Minute Epoxy and glue the plates in place. Allow the epoxy to cure completely. Photo # 28 o 5) Install the servo using the wood screws provided with your radio system. Drill 1/16” pilot holes through the plates before installing the screws. This will help prevent the wood from splitting. WOOD SCREWS AILERON SERVO o o o o o {2} {2} {2} {2} {2} INSTALLING THE AILERON LINKAGE o 6) Thread one nylon adjustable control horn onto each aileron torque rod. Thread them on until the are 7/8” above the top surface of the wing. See figure # 8 below. PARTS REQUIRED 2mm x 85mm Wire Threaded w/L-Bend Nylon Clevises Nylon Snap Keepers Wing Servo Mounting Plate (W-25) Nylon Adjustable Control Horns Figure # 8 INSTALLING THE AILERON SERVO ADJUSTABLE CONTROL HORN o 1) Install the rubber grommets and brass collets onto your servo. Test fit the servo into the precut servo hole in the top side of the lower wing. The output shaft should be pointing towards the leading edge of the wing. 7/8” o 7) Thread one nylon clevis onto each of the two 2mm x 85mm threaded rods with Lbends. Because the size of servos differ, you may need to adjust the size of the precut opening. You may also need to use a modeling knife and cut a groove to allow room for the servo wire to exit the hole. o 8) With the servo centered, install one dual takeoff servo arm onto the servo. The arm should be installed so it is parallel with the trailing edge of the wing. o 2) Remove the servo and position the two servo mounting plates (W-25) on the wing. The plates should be centered from side to side and the inside edge should be even with the servo opening. See photo # 29 below. o 9) Use a couple of pieces of masking tape, taped between the ailerons and the trailing edge of the wing, to hold the two ailerons in neutral. Photo # 29 o 10) Snap the clevises onto the adjustable control horns. With the servo arm and ailerons centered, push the L-bends down through the holes in the servo arm. Adjust the length of the wires by turning the nylon clevises in or out until the correct length is achieved. Hold the wires in place using two nylon snap keepers. See photo # 30 at top right. MOUNTING PLATE MOUNTING PLATE 1 7 Photo # 30 SNAP KEEPER servos should be pointing towards the front of the fuselage. See photo # 32 below. SERVO ARM PUSHROD WIRE Photo # 32 CLEVIS R CONTROL HORN E E = ELEVATOR T = THROTTLE R = RUDDER o 11) When satisfied with the alignment, install the servo arm set screw and remove the masking tape from the ailerons. T Because the size of servos differ, you may need to adjust the size of the precut openings. You may also need to use a modeling knife and cut a groove to allow room for the servo wires. RADIO INSTALLATION PARTS REQUIRED o {1} Fuselage Servo Tray (D-15) o {2} Balsa Support Rails (D-30) o 4) Install the servos using the wood screws provided with your radio system. Drill 1/16” pilot holes through the tray before installing the screws. This will help prevent the wood from splitting. INSTALLING THE SERVO TRAY o 1) Trial fit the servo tray (D-15) in position inside the fuselage. The tray should rest on top of the preinstalled balsa supports glued to the fuselage sides. The front edge of the tray should be 1-1/4” behind the front bulkhead. See photo # 31 below. INSTALLING THE RECEIVER & BATTERY o 5) Plug the servo leads into the receiver. Looking from behind the airplane the left servo is the for throttle, the center servo is for elevator and the right servo is for rudder. Plug the aileron extension and switch that came with your radio system into the receiver as well. Photo # 31 o 6) Wrap the receiver and battery pack in foam rubber to protect them from vibration. Position them under the servo tray, using extra foam rubber to hold them in place. FRONT EDGE o 2) When satisfied with the fit, remove the tray and mix up a generous amount of Kwik Bond 5 Minute Epoxy. Glue the tray in place using the epoxy. Before the epoxy sets, glue the two balsa support rails (D-30) in place. They are positioned on top of the servo tray, directly above the lower support rails. Allow the epoxy to cure fully before proceeding. Because of the length of the Ultimates nose, the receiver and battery should be positioned at the rear of the servo compartment. This will be especially true if using a four stroke engine. INSTALLING THE SERVOS INSTALLING THE SWITCH o 3) Install the rubber grommets and brass collets onto your remaining three servos. Test fit the servos into the precut servo holes in the servo tray. The output shaft of the center servo should be pointing towards the back of the fuselage. The output shaft of the two outer o 7) Mount the switch to the fuselage side at the rear of the servo compartment. Use the faceplate of the switch itself to locate at make the necessary cutouts and holes. 1 8 o 8) Using a 1/16” drill bit, drill a hole through the side of the fuselage for the antenna to exit. Route the antenna out the fuselage and secure it to the vertical fin using a rubber band. See figure # 9 below. Figure # 9 o 5) Remove the excess throttle pushrod wire using wire cutters. See photo # 33 below. CONNECTOR Photo # 33 PUSHROD WIRE SERVO ARM CUT RUBBER BAND ANTENNA MODIFIED SERVO ARM o 6) Test the movement of the throttle pushrod. Full forward stick and full forward trim should result in the carburetor barrel opening completely. Full down stick and full forward trim should result in the approximate idle setting. Full down stick and full down trim should result in the carburetor barrel closing fully. THROTTLE LINKAGE PARTS REQUIRED o {1} Adjustable Servo Connector Assembly INSTALLING THE THROTTLE CONNECTOR o 1) Install one adjustable servo connector through the second hole out from the center of one servo arm. You may have to enlarge the hole in the servo arm to accommodate the servo connector. Remove the excess material from the servo arm using wire cutters. See figure # 10 below. Figure # 10 o 7) When satisfied that the pushrod linkage is adjusted correctly and no binding is present, install the servo arm set screw. RUDDER PUSHROD SET SCREW PARTS REQUIRED SERVO CONNECTOR SERVO ARM o o o o o o o o NUT After installing the adjustable servo connector apply a small drop of Kwik Bond Thin C/A to the nut. This will prevent the connector from loosening during flight. {1} {2} {1} {1} {1} {1} {1} {1} Nylon Control Horn w/Nylon Back Plate 2mm x 15mm Machine Screws 700mm Nylon Pushrod 2mm x 120mm Wire Threaded Both Ends 2mm x 85mm Threaded Wire w/L-Bend Nylon Snap Keeper Nylon Clevis Pushrod Support (D-32) INSTALLINGTHERUDDERCONTROLHORN o 1) The centerline of the rudder control horn is located on the left side of the rudder (looking from behind) 1-3/8” up from the bottom of the rudder. Position the control horn so the clevis attachment holes are directly in-line with the hinge line. The control horn should also be parallel with the hinge line. See figure # 11 below. o 2) Turn on the radio system. Check to ensure that the throttle servo output shaft is moving in the correct direction. o 3) Slide the adjustable servo connector/ throttle arm assembly over the end of the throttle pushrod wire. Position the throttle stick and the throttle trim at their lowest positions. Figure # 11 o 4) Manually push the carburetor barrel fully closed. Attach the servo arm to the servo angled back about 45º from center. With the carburetor barrel fully closed, tighten the set screw in the adjustable servo connector. 1 9 o 2) When satisfied with the alignment, use a 3/32” drill bit and the control horn as a guide and drill the mounting holes through the rudder. o 10) Slide the pushrod back into the pushrod housing. Snap the clevis onto the rudder control horn and use a couple of pieces of masking tape to hold the rudder in neutral. o 3) Mount the control horn to the rudder by inserting the 2mm x 15mm machine screws through the control horn mounting base, through the rudder and into the backplate. Tighten the screws, but do not overtighten them. You do not want to crush the wood. o 11) Locate a long servo arm and using wire cutters, remove all but one of the arms. Install the L-bend in the 85mm wire into the outer hole in the servo arm. Secure the wire in place using one nylon snap keeper. INSTALLING THE RUDDER PUSHROD o 12) With the rudder and rudder servo in neutral, install the servo arm onto the servo. The arm should be positioned perpendicular to the fuselage sides. o 4) Thread the 2mm x 120mm threaded wire into one end of the 700mm nylon pushrod. For safety, thread the wire no less than 5/16” into the pushrod. o 13) Using a pen, place a mark on the nylon rudder pushrod where the tip of the wire overlaps it. Use a modeling knife and cut off the nylon pushrod 5/16” ahead of the mark. This will leave enough space so the threaded wire can thread into the pushrod at least 5/16”. o 5) Thread the nylon clevis onto the opposite end of the 2mm x 120mm threaded wire. It should be threaded no less than 5/16” onto the wire also. o 6) Using a modeling knife remove the covering from over the rudder pushrod exit slot. Looking from the back of the airplane, the slot is located on the left side of the fuselage, 6” forward of the rudder hinge line and 1-1/4” below the horizontal stabilizer. o 14) Thread the wire into the pushrod. You can thread it in further or back it out to achieve the correct length. o 15) When satisfied with the alignment, install the servo arm set screw and remove the masking tape from the rudder. See photo # 35 below. o 7) Insert the plain end of the nylon pushrod into the fuselage from the back. Snap the clevis onto the rudder control horn. Move the rudder back and forth to ensure there is no binding. See photo # 34 below. Photo # 35 CONTROL HORN PUSHROD WIRE SERVO ARM Photo # 34 PUSHROD SUPPORT CLEVIS SNAP KEEPER PUSHROD WIRE PUSHROD HOUSING o 16) Move the rudder back and forth. There may be some flex present in the pushrod just before it gets to the rudder servo. If so, glue one pushrod support (D-32) between the pushrod housing and the servo tray using a small amount of Kwik Bond 5 Minute Epoxy. See photo # 35 above. o 8) Remove the pushrod from the pushrod housing. Using a ruler and pen, measure forward on the pushrod housing 4” from where the pushrod housing enters the servo compartment from the rear bulkhead. o 9) Using a modeling knife, cut off the pushrod housing at this mark. 2 0 o 4) Using a 3/32” drill bit, drill a hole through the center of the nylon joiner plate. Slide a 2mm washer onto the 2mm x 20mm machine screw. Slide the screw through the center hole of the nylon joiner plate. ELEVATOR PUSHROD PARTS REQUIRED o o o o o o o o o o o {2} {4} {2} {2} {3} {1} {2} {4} {1} {1} {1} Nylon Control Horns w/Nylon Back Plates 2mm x 15mm Machine Screws 600mm Nylon Pushrods 2mm x 100mm Wire Threaded Both Ends Nylon Clevises (one w/1.5mm I.D. Hole) Nylon Joiner Plate 2.2mm x 10mm Wood Screws 2mm Flat Washers 2mm x 20mm Machine Screw 2mm Hex Nut Pushrod Support (D-32) o 5) Slide a second 2mm washer onto the machine screw and then thread on the 2mm nut. Tighten the nut completely and secure it in place using Kwik Bond Thin C/A. Let the C/A cure completely and double check to ensure the screw and nut do not move. INSTALLINGTHEELEVATORCONTROLHORNS We don't recommend using any types of thread lock or C/A accelerators. The chemicals in these items can destroy the nylon parts. o 1) The centerline of the elevator control horns are located on the bottom side of each elevator half, 1” out from the fuselage sides. Position the control horns so the clevis attachment holes are directly in-line with the hinge line. The control horns should also be parallel with the hinge line. See figure # 12 below. o 6) Slide one 2mm washer over two 2.2mm x 10mm wood screws. Slide the wood screws through the two outer holes in the nylon plate and thread them into the two 600mm nylon pushrods. See photo # 36 below. Figure # 12 Photo # 36 PUSHROD TUBES NYLON PLATE MACHINE SCREW o 2) When satisfied with the alignment, use a 3/32” drill bit and the control horns as a guide and drill the mounting holes through the elevator halves. WOOD SCREW NUT We highly recommend installing the two wood screws using Kwik Bond 5 Minute Epoxy to help prevent any possible chance of them pull out during flight. o 3) Mount the control horns to the elevator halves by inserting the 2mm x 15mm machine screws through the control horn mounting bases, through each elevator half and into the backplates. Tighten the screws, but do not overtighten them. You do not want to crush the wood. INSTALLING THE ELEVATOR PUSHROD o 7) Thread one nylon clevis with 1.5mm I.D. hole onto the end of the 2mm x 20mm machine screw. INSTALLING THE PUSHROD JOINER o 8) Using a modeling knife remove the covering from over the two elevator pushrod exit slots. Looking from the back of the airplane, the slots are located on each side of the fuselage, 6” forward of the rudder hinge line and 1” below the horizontal stabilizer. The elevator control system uses two pushrods which are connected together just before they reach the elevator servo. See figure # 13 below. Figure # 13 PUSHROD TUBES 2.2mm x 10mm WOOD SCREW NYLON PLATE 2mm x 20mm MACHINE SCREW o 9) Using a ruler and pen, measure forward on both pushrod housings 4” from where the pushrod housings enter the servo compartment from the rear bulkhead. 2mm WASHER 2mm WASHER 2 1 o 10) Using a modeling knife, cut off the pushrod housings at this mark. o 19) Move the elevator halves up and down. There may be some flex present in the pushrod just before it gets to the elevator servo. If so, position one pushrod support (D-32) between the two pushrod housings and the servo tray. Using a small amount of Kwik Bond 5 Minute Epoxy glue the housings to the support and the support to the tray. o 11) Slide the nylon pushrods into the pushrod housings and out the exit slots. o 12) Locate a long servo arm and using wire cutters, remove all but one of the arms. With the elevator servo in neutral, install the servo arm onto the servo. The arm should be positioned perpendicular to the fuselage sides. AILERON LINKS PARTS REQUIRED o 13) Snap the clevis through the outer hole in the servo arm. o o o o o o 14) Thread one clevis onto one end of each 2mm x 100mm threaded wire. {4} {8} {2} {2} {2} Nylon Control Horns w/Nylon Back Plates 2mm x 15mm Machine Screws 2mm x 200mm Wire Threaded w/L-Bend Nylon Clevises Nylon Snap Keepers INSTALLING THE CONTROL HORNS o 1) Using a modeling knife, carefully cut the four control horns to shape. See figure # 14 below. o 15) Snap one clevis/wire assembly onto each elevator control horn. Use a couple of pieces of masking tape to hold each elevator half in neutral. Figure # 14 o 16) Working with one half only, use a pen and place a mark on the nylon elevator pushrod where the tip of the wire overlaps it. Use a modeling knife and cut off the nylon pushrod 5/16” behind the mark. This will leave enough space so the threaded wire can thread into the pushrod at least 5/16”. o 2) The control horns are located both on the top and bottom ailerons. They should be positioned 6-1/4” in from the tip of each aileron. The control horns for the top wing mount on the bottom of the ailerons and the control horns for the bottom wing mount on the top of the ailerons. Mount the control horns with the clevis attachment holes facing the back of the airplane. See photo # 38 below. o 17) Thread the wire into the pushrod. You can thread it in further or back it out to achieve the correct length. Repeat steps # 14 - # 17 for the opposite side. o 18) When satisfied with the alignment, install the servo arm set screw and remove the masking tape from the elevator halves. See photo # 37 below. Photo # 38 TRAILING EDGE Photo # 37 PUSHROD SUPPORT SERVO ARM CLEVIS CONTROL HORN o 3) When satisfied with the alignment of all four control horns, use a 3/32” drill bit and the control horns as a guide and drill the mounting holes through the ailerons. JOINER ASSEMBLY 2 2 o 3) Using a pen, place a mark on both sides of the canopy at the front and back. Place the marks where the canopy meets the bottom of the black stripe on the fuselage sides. o 4) Mount the control horns to the ailerons by inserting the 2mm x 15mm machine screws through the control horn mounting bases, through the ailerons and into the backplates. Tighten the screws, but do not overtighten them. You do not want to crush the wood. o 4) Using a 3/32 drill bit, drill four mounting holes through the canopy only. Locate two holes on each side, near the cockpit. Use the photo below for reference. See photo # 40 below. INSTALLING THE AILERON LINKS o 5) Plug in the aileron servo to the receiver and install the top and bottom wings. Use a couple of pieces of masking tape to hold the top wing ailerons in neutral. Turn on your radio system and center the bottom wing ailerons. Photo # 40 MOUNTING HOLE o 6) Thread a nylon clevis onto the threaded end of each 200mm wire. Slide the L-bend of each wire through the lower hole in the top aileron control horns. Secure the wires in place using two nylon snap keepers. PLACE MARK PLACE MARK o 5) Secure the canopy in place using four 2mm x 10mm wood screws threaded into the fuselage. o 7) With all four ailerons in neutral, adjust the nylon clevis and snap it through the top hole in the lower control horns. See photo # 39 below. o 6) Remove the canopy. Using a modeling knife or Lexan Canopy Scissors, trim the canopy across the bottom of each side at the marks you made earlier. Install the optional aftermarket pilot at this also. Photo # 39 PUSHROD WIRE MOUNTING HOLE NYLON CLEVIS o 7) To give the canopy a better appearance on the fuselage, we suggest you paint the portions that overlap the top of the fuselage. We used Coverite 21st Century Red # COVR0102. Remember to lightly sand any portion that will be painted so the paint sticks. Use white and black trim tape to match the area of the canopy that overlaps the sides of the fuselage. SNAP KEEPER CONTROL HORN CANOPY COWLING PARTS REQUIRED PARTS REQUIRED o {1} Clear Canopy o {4} 2mm x 10mm Wood Screws o {1} Fiberglass Cowling o {4} 3mm x 6mm Wood Screws TRIMMING THE CANOPY MOUNTING THE COWL o 1) Using a modeling knife or Lexan Canopy Scissors, cut out the canopy along the molded scribe lines. o 1) Remove the carburetor and muffler from the engine. Use plastic or masking tape to cover the carburetor, muffler and glow plug openings in the engine to prevent dust from entering. o 2) Trial fit the canopy. When you have adjusted the canopy so it is straight, hold it in place using a couple pieces of masking tape. 2 3 o 2) Using a Dremel Tool with a sanding drum attachment, carefully open the two air inlets in the front of the cowl. Trim away a small amount at a time so you don't remove too much material. See photo # 41 below. Photo # 41 o 7) Remove the cowl and enlarge the holes in only the cowl using a 5/64” drill bit. Reinstall the cowl and secure it in place using the four wood screws. See photo # 42 below. Photo # 42 MAKE CUT OUT (BOTH SIDES) MOUNTING HOLE LOCATIONS o 3) Slide the cowl onto the fuselage. Install your spinner backplate onto the engine and secure it in place. Use the backplate to align the front of the cowl. The spinner backplate diameter should match the outer diameter of the spinner ring on the cowl, not fit inside it. It may also be necessary to trim the bottom of the cowl so it does not interfere with the landing gear. o 8) Locate and the areas of the cowl that need to be removed for access to the high and low speed needle valves, glow plug, muffler and if necessary, engine head clearance. o 9) Remove the cowl and make these cutouts using a Dremel Tool with a sanding drum attachment. Holes for the needle valves can be cut using a drill bit. We highly suggest the use of a Dubro Fuel Filler Valve to fuel the airplane. This should be mounted to the cowling at this time also. o 4) With the front of the cowl aligned with the spinner backplate, double check that the cowl lines up with the fuselage. When satisfied with the fit, use a couple of pieces of masking tape to hold the cowl firmly in position. o 10) Install your muffler (stock or Pitt's Style) and connect your fuel and pressure lines to the fuel tank and fueling valve. If you are using a two stroke engine with a stock muffler a 1” muffler extension will be necessary. No extension is necessary if using a four stroke engine or a two stroke engine with an aftermarket Pitt's Style muffler. o 5) The cowl is held in place using four 3mm x 6mm wood screws threaded into the firewall. Two screws are located on the top, one on each side towards the bottom of the cowl. Use a ruler and pen to locate and mark the mounting screw locations. o 11) Once you are satisfied with the fit of the cowl and all access holes have been cut, remove the cowl and paint it with Coverite 21st Century Gloss Clear # COVR1265 to prevent raw fuel from damaging the paint. o 6) Using a 1/16” drill bit, drill four pilot holes through the cowl and about 1/2” into the firewall at the locations you marked. o 12) After the clear coat has dried, connect the fuel lines to the muffler, fuel filler valve and carburetor. Reinstall the cowl and secure it in place. Install the prop and spinner. 2 4 LATERAL BALANCE BALANCE After you have balanced your Ultimate on the C.G. you must laterally balance it. Doing this will help the airplane track better in vertical maneuvers and loops. o 1) It is critical that your airplane be balanced correctly. Improper balance will cause your plane to lose control and crash. The center of gravity is located 4” back from the leading edge of the top wing, at the center section. This location is recommended for initial test flying and trimming. There is a 3/8” margin forward and aft, but it is not recommended that the center of gravity be located any further back than 4-3/8”. Balance the Ultimate right side up with the fuel tank empty. o 1) Turn the airplane upside down. With the wings level carefully lift the airplane by the engine crankshaft and the tail wheel bracket. This may require two people to make it easier. o 2) If one side of the wing falls, that side is heavier than the opposite. Add small amounts of lead weight to the bottom side of the lower wing. Follow this procedure until the wings stay level when you lift the airplane. o 2) Mount the wings to the fuselage. Using a couple of pieces of masking tape, place them on the bottom side of the top wing 4” back from the leading edge, at the center section. CONTROL THROWS o 1) We highly recommend setting up the Ultimate using the control throws listed below. We have listed control throws for both initial test flying/sport flying and aerobatic flying. o 3) Place your fingers on the masking tape and carefully lift the plane. o 2) Turn on the radio system and with the trim tabs on the transmitter in neutral, center the control surfaces by making adjustments to the clevises. The servo arms should be centered also. o 4) If the nose of the plane falls, the plane is nose heavy. To correct this first move the battery pack further back in the fuselage. If this does not correct it, stick small amounts of weight on the fuselage under the horizontal stabilizer. If the tail of the plane falls, the plane is tail heavy. To correct this, move the battery and receiver forward or stick weight onto the firewall or inside the front section of the cowl. When balanced correctly, the airplane should sit level or slightly nose down when you lift it up with your fingers. o 3) When the elevator, rudder and aileron control surfaces are centered, use a ruler and check the amount of the control throw in each surface. The control throws should be measured at the widest point of each surface! INITIAL FLYING/SPORT FLYING Ailerons: Elevator: Rudder: 3/16” up 7/16” up 1” right 3/16” down 7/16” down 1” left AEROBATIC FLYING Once you have flown and trimmed the Ultimate, the balance point can be moved forward or aft 3/8” to change the flight performance. Moving the balance point back will cause the Ultimate to be more responsive, but less stable. Moving the balance point forward will cause the Ultimate to be more stable, but less responsive. Do not fly the Ultimate beyond the recommended balance range or an uncontrollable crash could result! Ailerons: Elevator: Rudder: 5/16” up 3/4” up 1-1/2” right 5/16” down 3/4” down 1-1/2” left Do not use the aerobatic settings for initial test flying or sport flying. 2 5 o 4) By moving the position of the clevis at the control horn toward the outermost hole, you will decrease the amount of throw of that control surface. Moving the clevis toward the control surface will increase the amount of throw. NOTES ____________________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ____________________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ____________________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ____________________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ______________________________________________ ____________________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ ______________________________________________ ______________________________________________ _____________________________________________ FLYING The Ultimate is designed for those pilots who are experienced in flying sport models. It is in no way a trainer. If you do not feel comfortable that you are able to test fly the airplane don't hesitate to ask someone for some help getting it tested and trimmed out. Typically aerobatic airplanes, such as the Ultimate, require some different flying techniques that you might not be familiar with. It is very important to let the airplane get up to flying speed before lifting off. Pulling the plane off the ground too fast will cause the airplane to stall and crash. You should allow the plane to roll out until the tail is completely off the ground and flying. Allow the airplane to roll out about 50 feet more and gently pull it off the ground and into a shallow climb out. In the air, the plane flies like any other sport aerobatic plane. Loops, rolls, low passes and most all other maneuvers are all possible. Because of the sometimes excessive control throws used for aerobatics you must be aware of high speed stalling. This is when the airplane is at full power and too much up elevator is input at once. It causes the airplane to snap. To prevent this, make sure the elevator is set up to our recommended test flying and sport flying settings. When set up to aerobatic settings, be gentle on the elevator. When it is time to land always bring the airplane in with a small amount of power. It is not a good habit to just chop the throttle and dive the airplane to the ground. Just like the real airplanes, gradually reduce power along with altitude and speed. When you are about 2-3 feet off the ground, reduce power to idle and gently let the airplane settle onto the runway. Be careful not to over control. 2 6 TRIM CHART After you have test flown and done the initial trim changes to the aircraft, use the Trim Chart below to begin trimming your airplane. Following and adhering to this chart will result in the ability to diagnose trim problems and correct those problems using the simple adjustments shown below. Making these observations and related corrections will result in a truer, better flying airplane. TRIMFEATURE MANUEVER OBSERVATION CORRECTION Control Centering Fly general circles and random maneuvers. Try for hands off straight and level flight. Readjust linkages so Tx trims are centered. Control Throws Fly random maneuvers. A) Too sensitive, jerky controls. B) Not sufficient control. If A) Change linkages to reduce throws. If B) Increase throws. Engine Thrust Angle* From straight flight, chop throttle quickly. A) Airplane continues level path for short distance. B) Airplane pitches nose up. C) Airplane pitches nose down. If A) Thrust is correct. Center of Gravity Longitudinal Balance Yaw** Lateral Balance Aileron Rigging If B) Decrease downthrust. If C) Increase downthrust. From level flight, roll to 45º bank and neutralize controls. A) Continues in bank for moderate distance. B) Nose pitches up. C) Nose drops. Into wind, do inside loops using only elevator. Repeat tests doing outside loops from inverted entry. A) Wings level throughout. B) Yaws to right in both inside and outside loops. C) Yaws to left in both inside and outside loops. D) Yaws to right on inside, and left on outside loops. E) Yaws left on inside, and right on outside loops. If A) Trim is correct. If B) Add left rudder trim. A) Wings are level and plane falls to either side. B) Falls off to left in loops. Worsens as loops tighten. C) Falls off to right in loops. Worsens as loops tighten. If A) Trim is correct. Into wind, do tight inside loops. With wings level, pull to vertical climb and neutralize controls. A) Climb continues along same path. B) Nose tends to go to inside loop. C) Nose tends to go to outside loop. If A) Trim is good. If B) Add nose weight. If C) Remove nose weight. If C) Add right rudder trim. If D) Add left aileron trim. If E) Add right aileron trim. If B) Add weight to right wing tip. If C) Add weight to left wing tip. If A) Trim is correct. If B) Raise both ailerons very slightly. If C) Lower both ailerons very slightly. *Engine thrust angle and C.G. interact. Check both. **Yaw and lateral balance produce similar symptoms. Note that the fin may be crooked. Make certain both elevator halves are even with each other and produce the same amount of control throw. Right and left references are from the rear of the plane, as if you were in the cockpit. 2 7 Since you love your new Ultimate Biplane, now how about this Global ARF performance airplane to go along with it? SPECIFICATIONS: Length...............47.25in Span.......................52in Area.................570sq.in Flying Weight...5-5.5lbs Engine.....45-53 2-stroke 52-60 4-stroke Radio..............4 channel ü All Wood Construction ü Prebent Aluminum Landing Gear ü Prepainted Fiberglass Cowling ü Prepainted Molded Wheel Pants ü Clear Molded Canopy ü Lightweight and Fast for Big Performance 2 8 Since you love your new Ultimate Biplane, now how about this Global ARF performance airplane to go along with it? SPECIFICATIONS: Length....................42in Span.......................52in Area.................362sq.in Flying Weight...5-5.5lbs Engine.....45-53 2-stroke 52-60 4-stroke Radio..............4 channel ü All Wood Construction ü Custom Spinner ü Prepainted Fiberglass Cowling ü Molded Wheel Pants ü Clear Molded Canopy ü Incredible Aerobatic Performer 2 9 Since you love your new Ultimate Biplane, now how about this Global ARF performance airplane to go along with it? SPECIFICATIONS: Span.......................59in Area.................620sq.in Empty Weight......3.5lbs Engine.....40-46 2-stroke 52-60 4-stroke Radio...........4-5 channel ü All Wood Construction ü Ready for Retracts ü Prepainted Fiberglass Cowling ü Prepainted Wheel Pants for Fixed Gear ü Clear Molded Canopy ü Big Pattern Performance In a Midsize Package 3 0 ** PRODUCT EVALUATION SHEET ** Telling us what you like and don't like determines what model kits we make and how we make them. We would appreciate it if you would take a few minutes of your time to answer the following questions about this kit and your modeling interests. Simply fold this form on the dotted lines, seal with tape and mail it to us. Do not use staples and make sure our address faces out. 1.) Kit: Ultimate Biplane .46 (123820) 2.) Where did you learn about this kit? o Magazine Ads o Friend o Hobby Shop o Other 7.) Was any of the model's assembly difficult for you? If yes, please explain. __________________________________ __________________________________ __________________________________ 3.) What influenced you the most to buy this kit? 8.) What did you like most about this kit? o Magazine Ads o Price o Assembly Manual o Parts Fit o Type of Model o Box Art o Hardware Supplied oOther_________ o Recommendation o Other__________ __________________________________ __________________________________ 4.) Did you have any trouble understanding the written instructions? If yes, please 9.) What did you like least about this kit? explain. o Assembly Manual o Parts Fit o Yes o No o Hardware SuppliedoOther_________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________10.) Are you satisfied with the finished model? 5.) Did you have any trouble understanding o Yes o No any of the photographs in the instructions? If no, please explain. If yes, please explain. _________________________________ o Yes o No _________________________________ __________________________________ _________________________________ __________________________________ __________________________________11.) How does this kit compare to similar kits __________________________________ by other manufacturers? o Better Than o As Good 6.) Were any of the kit parts: o Not as Good o Damaged o Wrong Size o Missing o Wrong Shape 12.) Please list any other comments or suggestions you have. If you checked any of the boxes above, _________________________________ please list the parts below: _________________________________ __________________________________ _________________________________ __________________________________ _________________________________ 3 1 Fold along dotted line Place Stamp Here Global Hobby Distributors Attn: Customer Service Department 18480 Bandilier Circle Fountain Valley, CA. 92728 Fold along dotted line 3 2