HeliumMG2 v1.00b 02022010

© 2008 Stevens AeroModel. Page 1 of 52

HeliumMG2 motorized glider / FPV platform

A A

B B

A

B

HS-65HB

DD

R10

R9

R11

R6

LE3

LE3

C C

C

C

CC

C

C

(He) MG2

Instruction Manual - Version 1.00b (02022010)

Span 77.75 in. / Length 44.5 in. / Area 645 Sq. In. / Weight 25 oz.

Made in the USA! Of U.S. and Imported Parts


***Cautions***

1. Power system.

Overpowering this model with a heavier / more powerful system is not recommended. Stevens AeroModel recommends a power system no greater than 300W, a maximum pitch speed of 50 mph, and a maximum all up weight (AUW) of 36 oz.

Outrunner motors like the Hacker A30 transmit a great deal of stress to the motor mount. DO NOT run your motor up until you have verified that your blade is accurately balanced and in perfect track. Finally, disable your ESC’s prop braking function.

2. Throttle management.

Similar to full-scale and giant scale models this high performance model requires careful throttle management. When tracking through a down-line it is mandatory to govern the use of throttle, slowing the models descent, to avoid over speeding the airframe.

WARRANTY

Stevens AeroModel guarantees this kit to be free from defects in both material and workmanship at the date of purchase. This warranty does not cover any component parts damaged by use or modification. In no case shall Stevens AeroModel’s liability exceed the original cost of the purchased kit. Further, Stevens AeroModel reserves the right to change or modify this warranty without notice.

LIABILITY RELEASE In that Stevens AeroModel has no control over the final assembly or material used for final assembly, no liability shall be assumed nor accepted for any damage resulting from the use by the user of the final user-assembled product. By the act of using the user–assembled product, the user accepts all resulting liability. If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised to return this kit immediately in new and unused condition to the place of purchase. THIS PRODUCT IS NOT INTENDED FOR CHILDREN 12 YEARS OF AGE OR YOUNGER WARNING: This product may contain chemicals known to the State of California to cause cancer and or birth defects or other reproductive harm.


REQUIRED TO COMPLETE KIT: Kit Contents: Laser Cut Wood (21 Sheets – See inventory on following pages) Computer Drawn Plan Set Illustrated Instruction Manual Flat Stock and Push-Rods:

o 4 - 1/4 in. x 24 in. Square Balsa Leading Edge o 1 - Pre-Bent Landing Gear (0.125 in.) o 2 - 48 in. length Flat Carbon Fiber Stock o 1 - DuBro Micro2 30in Pushrod System (DUB922) o 1 - Pair 2-1/4 in. foam wheels

Large Hardware Bag: (4x6 Bag):

o 1 - Pair Delrin wing tip joiners o 1 - Package Rubber Bands #33 o 1 - 4 in. length 1/16 in. aluminum tubing o 1 - 4 in. length 1/32 in. music wire o 3 - 3/16 in. x 3.75 in. Hardwood Dowels

Small Hardware (2x3 Bag):

o 1 - 1 in. length 3/32 in. ID silicone fuel tubing o 2 - DuBro Micro2 Control Horns (1 pkg. / DUB919) o 2 - DuBro Mini EZ Connectors (1 pkg. / DUB845) o 2 - 1/8 in. star washers (wheel retainers) o 2 - 4-40 x 3/8 in. Nylon Machine Screw o 2 - 4-40 x 1-1/2 in. Nylon Machine Screw o 4 - 15/32 in. x 1/8 in. OD Aluminum Tubing (anti rotation pins) o 4 - 4-40 x 3/8 in. Machine Screw (motor mounting) o 4 - #2 x 1/4 in. Screw (A20-20L motor mounting) o 4 - assorted small black rubber bands o 8 - 4-40 Blind Nut o 10 - 3/16 in. Neo. Magnet

Recommended Finishing Items:

1. 2 Rolls of AeroFILM or AeroFILM Lite (Solarfilm, Solarfilm Solite, or Nelson Lite Film may be substituted).

Suggested Electronics:

1. 2 – High performance micro servos (Hitec HS-55 or HS-65) 2. 1 – Hitec HS-56 sub micro servo (for spoiler installation) 3. 1 – 6 in. servo extension (for spoiler installation) 4. 1 – Full range micro receiver (Castle Creations/Berg Micro Stamp 4 or 4L) Power Systems: 1. Hacker A30-28S, E-Flite Park 480 1020kv, SA Sport 480 A2810-11 2. 9x5-10x5 APC-E Propeller. If you desire to utilize a folding propeller you will be required to reverse the motor

shaft of the Hacker and VSport motor - Out of the box the E-Flite motor is better prepared to accept a collet style yoke and folding propeller assembly. We suggest using high quality Aeronaut Blades and an aluminum yolk assembly. See www.stevensaero.com for suggested items for this model.

3. 11.1v 2100mAh LiPo (Rated for 15C discharge). 4. Castle Creations Thunderbird 36 or Phoenix 25 ESC – (Enable propeller braking)

Building Supplies Required:

1. Thin CA (super glue) and glue tips 2. Medium CA (super glue) and glue tips 3. Thread Locking Compound (Blue) 4. Hobby knife and blade(s) #11 and straight edge 5. Fine grit sand paper 250/400/600 and sanding block 6. Clear tape ¾” wide scotch or DuBro hinge tape. 7. Balsa wood filler 8. .047 in., 1/16 in., 1/8 in., and 3/16 in. drill bits.


Laser Cut Parts Inventory

Wing Parts

Balsa 1/16" A-HM

Balsa 1/16" AB-MH

Balsa 3/32" AB-MH

Balsa 1/16" ABC-MH

Balsa 1/16" AB-MH

Balsa 3/32" AB-MH

W6b

W6a

S2

S11

R7aR8aR9a

R10

R7

R8

R9

R6

W6

<- T5

<- T6

W6

R6

<- T6

<- T5

S11

S2

R6b

R10a

R7a R8a R9aR6b

R10a

SW

1

SW2

SW

3

SW4

SW5

SW2

SW

3

SW4

SW

5

S9

S9

R1a

R1b

R3aR2a

R4b

R4a

R3b

R1a

R1b

R3a R2a

R4b

R4a

R3b

S1a

S1b

R2

R4

R3

R5R2

R4

R3

R5

R2b

R2b

T4 ->

<- T4

S4

S6

S4

S6

F16

HEMG2 01/21

Fuselage Part

HEMG2 02/21

HEMG2 03/21

HEMG2 04/21

HEMG2 05/21

HEMG2 06/21

R10

R7

R8

R9


Wing Parts

Balsa 1/8" ABC-HM

Balsa 3/32" AB-MH

Balsa 3/32" AB-HM

Balsa 1/8" AB-MH

Balsa 1/8" ABC-HM

LE2

LE2

LE1

TE2

<- W5

R11

W7

W8

TE2

<- W5

R11

W7

W8

W8W8

S5b

S3b

W4b

SP1

SP2

T2a

TE1a

TE1b

LE1

W4a

W3

W2

W6

W3

W3

W3

W6

W2

W2 W2

S5a

S3a

T3b

T2b

T3a

T1b

T1a

R1

DOWEL JIG01

W1b

R1

HEMG2 07/21

HEMG2 08/21

HEMG2 09/21

HEMG2 10/21

HEMG2 11/21

UNDERSIDE TRAILING EDGE BEVEL 45 DEG.


Fuselage Parts

Balsa 1/16" ABC-MH

Balsa 3/32" AB-MH

Balsa 3/32" AB-MH

Balsa 1/8" ABC-HM

Balsa 3/32" AB-MH

Balsa 3/32" AB-MH

F13

F13

C C

F15a

A

B

AB

H1a

H1c

H2

F17

F15b

A

B

A B

H1b

F10

F10

A

B FSb

F12a

F12c

A

BFSb

F12b

F14

C

C

C

C

C

C

C

C

F11b

F11a

H3

H3

HEMG2 12/21

HEMG2 13/21

HEMG2 14/21

HEMG2 15/21

HEMG2 16/21

HEMG2 17/21


Fuselage Parts

Ply 1/32"

Balsa 1/8" AB-HM

Ply 1/16"

LPly 1/8"

H4

F5 TOP F6 FORWARD/TOP F7 FORWARD/TOP F8 FORWARD/TOP F9 TOP

R6aR5a

R5a R6a

F1 T

OP

F0 T

OP

F3 T

OP

F4 T

OP

F2 T

OP

D

DD

G1

G1

G2F19b

W1a

F19a

F19c

H1d

H3

F18

F18

LE3

S10

S10

S8

LE3

S8

SP3SP3

W6c

SP4

HEMG2 18/21

HEMG2 19/21

HEMG2 20/21

HEMG2 21/21


General Assembly Instructions

A A

B B

A

B

HS-65HB

DD

R10

R9

R11

R6

Thank you, for purchasing this Stevens Aeromodel HeliumMG2 – “2-Meter Motorized Glider / FPV Platform”. This kit provides the builder and pilot a refreshing change of pace from heavy “ARF” style plywood box airframe construction, and blends stick and tissue design methods of the past with state of the art CAD technology and precision interlocking laser cut parts. The result is something you will find truly exceptional to build and fly. Please keep in mind that this kit is intended for a novice-intermediate builder and novice-intermediate pilot as a 3 channel motor glider/trainer. If you do not meet these criteria it is recommended to seek help from a more experienced builder / pilot. Best Regards, Bill Stevens [email protected] Stevens AeroModel “Laser Engineered” P.O. Box 15347 Colorado Springs, CO 80935 Assembly Tips

READ THE INSTRUCTIONS and the plan sheet prior to starting any work! Tape plans to work table. Protect plans from glue spills using the poly tubing your kit was bagged in. Join all parts with Thin CA unless otherwise specified. DO NOT REMOVE THE PARTS FROM THE BALSA SHEETS UNTIL REQUIRED! DO NOT FORCE THE FIT. When in doubt, double check your parts. Removal of material should not be

required. If you feel that you have a poor connection, check first to see that the part is not upside down. Reference each piece against the plan sheet.

Making solid glue joints: Hold parts together on top of plan sheet using moderate pressure to fit parts. Wick Thin CA into joint. There is no need to pin parts to work table as all pieces interlock and self - jig.


Tail Feathers General Construction Notes: This kit features our proprietary Trus-Loc™ system as such typical “stick” type construction has been replaced by precisely cut “stick” components that are keyed to fit in only one direction. The “knuckles” of the truss are identified with an alpha-numeric use this to match adjoining truss components “A” to “A” and “B” to “B” etc. If a part does not fit properly chances are very good that you have the wrong part or the part is in backwards. Under no circumstances should you need to fill significant gaps or re shape the parts.

1. All of the parts to create the tail feathers are located on the 1/8 in. hard balsa sheets 17 and 18/21. Remove parts from the sheet with a sharp #11 hobby blade. Assemble the parts on top of your plan set using the drawings on the plan to reference part location and orientation. Frame up all tail feather components as illustrated below.

C C

C

C

DD

CC

C

C

2. With the balsa tail feather framework complete refer to the plan sheet and install provided carbon fiber flat stock

where indicated using medium CA glue.

3. Round the leading edge of the stabilizers leaving then sand a 45 degree bevel to the leading edge of all control surfaces (That’s Rudder and Elevator only) in preparation for tape hinges.


Fuselage General Construction Notes: This fuselage utilizes an improved tab and notch construction method developed by Stevens AeroModel. Each component precisely interlocks using unique tab and notch sizes to allow the parts to only fit in one direction. Where parts orientation can be reversed or inverted parts are scribed with a reference such as “top” or “front” for proper orientation. Throughout construction we suggest dry-fitting all components, and using minimal amounts of glue at tab and notch locations only to hold parts together. By dry fitting the fuselage, each successive component will assist with pulling the assembly square and straight.

1. Begin construction of the fuselage by completing the following sub assemblies: Build 3/32 in. balsa former F12 from parts F12a, F12b, and F12c (sheets 14 and 16/21). Build 1/16 in. balsa former F15 from parts F15a and F15b (sheet 12/21). Build two each 3/32 in. balsa fuselage sides FS from parts FSa, FSb, and corresponding truss parts (sheets 14, 15, and 16/21) when constructing fuselage sides use a straight edge to align part along bottom edge, see illustration below the following diagram. Build 3/32 in. balsa former F11 from parts F11a and F11b (sheet 13/21). Finally, build 3/32 in. balsa hatch component H1 from parts H1a, H1b, and H1c (sheet 13/21).

A A

B B

A

BFSa

FSb

H1b

H1a

H1c

F12a

F12c

F12b

F15a

F15b

F11a

F11b

F12 F15

F11 H1

FS

2. Reference plan set for location of provided 4-40 blind nuts based on selected motor type then install to back side of 1/8 in. lite plywood former F1 (sheet 21/21). The second photo in this series shows the F1 firewall with blind nuts installed as viewed from the front. Secure blind nuts with gap filling medium CA glue. Set F1 aside.


3. The 1/8 in. lite plywood central crutch F0 (sheet 21/21) is clearly marked “TOP” locate this part and invert so that you are looking at the underside of the part. Install two 4-40 blind nuts to holes just aft of servo pockets as illustrated below. Secure blind nuts with medium CA glue. Do not allow glue to come into contact with internal threads of blind nuts. The second photo below shows the F0 central crutch with blind nuts installed as viewed from the topside.

4. Install the 1/16 in. ply former F3 (sheet 20/21) by inserting it through the lightening hole central to the F0 central crutch then aligning the notches in F3 with the crutch sides and gently twisting it into location. See illustration below. Make certain that the etching on F3 faces forward and to the top-side of the crutch assembly.

5. The 1/8 in. lite plywood parts F2 and F4 (sheet 21/21) are installed to the central crutch as illustrated below. Make certain that the etching on these parts faces forward and to the top side of the central crutch.


6. Locate the 1/16 in. ply former F5 (sheet 20/21) and dry fit to the central crutch as illustrated below. Again, pay attention to proper top side and forward orientation.

7. 1/16 in. ply part G1 (sheet 20/21) key to center crutch assembly as illustrated below. Tack glue G1 to the F3

former to assist with retaining this part.

8. Key the completed central crutch assembly to one of the FS 3/32 in. fuselage sides and bond with thin CA glue at tab and notch locations. Next install the F1 firewall to the fuselage assembly observing proper top and front orientation and bond to assembly using thin CA glue. Complete step by joining the second FS fuselage side to the opposite side of the central crutch. With full access to central crutch, fuselage sides, and F1 firewall now is the best time to build up a solid glue fillet (use medium gap filling CA) where F1 meets the crutch and fuselage sides.


9. Install the 1/16 in. balsa forward cross-grain fuselage doubler F10 (sheet 12/21) as illustrated below. Match the 3/16 in. hole in F10 with that of the fuselage sides. Bond using medium CA glue.

10. Install 3/32 in. balsa part F12 (previously assembled in step 1) to top (curved) surface of fuselage assembly as illustrated below. Retain by tack gluing with thin CA at tab and notch locations.

11. Install the 1/16 in. plywood F18 wing dowel guides/fuselage side braces (sheet 20/21) using the tab and notch holes in F5 to align the parts. Retain with thin CA glue.


12. Install the 3/32 in. balsa former F11 (previously assembled in step 1)

13. Bond the 1/16 in. ply part G2 (sheet 20/21) into position directly aft of F15 as illustrated. Build up a solid glue fillet between G2 and surrounding structure on inside of fuselage.

14. Locate the following parts: 1/16 in ply former F9 (20/21) and 1/16 in. balsa part F16 (sheet 2/21). Key F16 to the back side of F9 using the notches in F9 to register the part. Now key the assembly to one of the fuselage sides as illustrated below. Retain parts with thin CA glue. Do not glue the second fuselage side to the assembly at this time.


15. Install two 4-40 blind nuts to one side of 1/8 in. balsa part F17 (sheet 17/22) then install F17 spanning aft end of fuselage and former F16 as illustrated in the second photo below.

Finally pull the second fuselage side together with these assembled parts and tack bond with thin CA glue.

16. Install the 1/16 in. balsa part F14 (sheet 12/21) to the underside of the fuselage assembly. F14 extends from F5 to laminate on top of F16. Tack glue this former to the fuselage at the tab and notch locations.


17. With the fuselage supported on your flat work table locate the 1/16 in ply parts F6, F7, and F8 (sheet 20/21). These parts also have a top and forward designation etched on them. Pay careful attention to the part orientation as you install and tack glue these to the fuselage assembly in their corresponding positions.

18. Install the 1/16 in. balsa aft cross grain doubler F13 (sheet 12/21) register part against the inside aft surface of former F5 and F14 aligning the 3/16 in. hole in the doubler with the matching hole in the fuselage sides as illustrated below. Bond part using medium CA glue.

19. Complete aft end of fuselage by installing 1/16 in. balsa part F15 (assembled in step 1) aligning tabs in former with notches in fuselage. F15 spans former F5 to the tail of the fuselage assembly. Tack glue to retain part.


20. Final Glue Fuselage. Revisit all tack glued parts, hold the fuselage flat and square on your building board and wick thin or medium CA glue along all part joints.

21. Complete the battery hatch catch assembly. Dry fit the 1/8 in. lite ply H3 (sheet 21/21) part as illustrated in the

first photo below. Now key the 1/16 in. balsa part H4 (sheet 20/21) to the fuselage on top of H3 and interlocking with former F5 as illustrated in the second photo. Square both parts, as one unit, to the former and retain with thin CA glue.

22. Locate the 3/32 in. balsa part H1 (assembled in step 1) on top of 3/32 in. balsa part H2 (sheet 13/21) matching. Drive the tabs of the 3/32 in balsa part H3 (sheet 13/21) through stacked H1/H2 parts at notch locations. H3 properly locates H1 and H2. Bond hatch components together using medium CA glue.

Set the hatch assembly on top of your work table so that you are looking at the outside surface of the parts. Bond the 1/32 in. ply part H1d to the exposed catch tab of the assembly as illustrated below.


23. Fill 3/16 in. diameter hole in battery hatch with a drop of medium CA glue then install one 3/16 in. diameter Neo. Magnet to hole as illustrated below. Seat magnet only so that it is flush with the outside surface of the battery hatch.

24. As magnets are polarized, attracting from one side and repelling when reversed, it is essential to identify the proper polarity and install corresponding catch magnet without reversing it. Take a second Neo. Magnet and allow it to “snap” itself to the previously installed catch magnet in the battery hatch. The magnet will automatically flip to its attractive pole. Use a permanent marker to mark the outside surface of this magnet.

Remove the free magnet from the battery hatch and install within the fuselage catch assembly as illustrated with the non-marked side exposed as illustrated below. Test the fit and function of your hatch. If satisfied that you’ve correctly installed the second magnet to “attract” commit the part with CA glue.

25. Final Sand Fuselage. Using a sanding block or bar and fine grit sand paper lightly sand the fuselage and shape

as desired in preparation for covering with AeroFILM or AeroFILM Lite.


Landing Skid

1. From the DuBro RC pushrod kit (DUB922) cut a 4-1/2 in. length of the 0.045 in. diameter wire. Use the plan set as a guide and bend this wire to the shape illustrated.

2. Locate the 1/16 in. ply part F19b (sheet 20/21) on top of 1/32 in. ply part F19a (sheet 19/21) matching the corresponding edges and laser drilled holes in each part. Bond together using medium CA glue. Once glue has cured test fit your bent tail skid wire to assembly and adjust fit if required. Bond tail skid wire within parts as illustrated below using medium CA glue.

3. Bond the F19c 1/32 in. ply part (sheet 19/21) on top of F19b to capture wire tail skid. Allow glue to cure then use the plan set once again as a reference an bend wire to final shape required by tail skid assembly. See illustration below.


Pushrod Housing Installation

1. From the DuBro RC pushrod kit (DUB922) thread the plastic push rod housing through the fuselage assembly as illustrated below. The pushrod housing passes through pre-cut holes in ply formers and exits fuselage through one of the partially cut exits. Complete one side at a time using the plan set as a reference start threading the housing from former F5 aft through fuselage. Housings will not cross so stick to the pre-drilled holes in the formers on the same side as your start hole.

2. Once your housing has reached one of the pre-defined exit points through the balsa top or bottom of the fuselage assembly remove the exit plug by completing the cuts in the top or bottom former to create an exit slot as illustrated below.

3. With the exit point plug removed complete the pushrod installation by allowing the pushrod to extend approximately 1/8 in. beyond the end of the exit point. Bond push rod housing at each capture point using CA glue then trim excess housing to extend only 3/16 in. forward of former F5 as illustrated below.


Control Linkage This section requires that you have completed and covered fuselage. Covering has been omitted from photographed fuselage

1. Temporarily mount horizontal fin using the provided 4-40 x 3/8 in. nylon bolts and tail skid assembly as

illustrated below. Then key vertical fin to fuselage and square to horizontal stabilizer. Tack glue vertical fin to retain position THEN REMOVE THE HORIZONTAL STABILIZER and thoroughly glue the vertical fin to permanently retain.

2. Using a hobby knife or 0.047 in. drill bit ream the holes of the provided DuBro Micro II Control Horns (DUB919) to readily accept the provided pushrod wire from the DuBro Micro II (DUB922) pushrod kit. Test fit wire to each hole position prior to installing control horn in next step.

3. Poke two holes in your covering over the pre-drilled install points for the control horn. Install the modified DuBro Micro II Control Horn (DUB919) at these pre-drilled points on Elevator and Rudder assembly to the corresponding side where your push rod housing exits the fuselage. See illustration below. Bond control horn to control surface using thin and medium CA glue. Trim barbed end of control horn where it extends beyond the opposite side of the control surface.


4. Slide the 0.045 in. wire push rods through the push rod housing and capture “L” bend with one each Du-Bro Micro II EZ Link as illustrated below. Note both parts are provided in your DUB922 pushrod kit. We suggest you read and execute the recommendations on the plan set for “Preventing In-Flight Failure of Worn EZ Link”.

5. Center the control surfaces and mount and center Rudder and Elevator control servos as illustrated in the plan set. Follow the instructions provided on the DuBro Pushrod kit for making final connections of push rod to servo control arm. Trim the push rods to overhang no more than ½ in. beyond the servo control arm.


Wing Center Section

1. Begin the wing assembly by building the following assemblies: Turbulators T1 from T1a/T1b, T2 from T2a/T2b, and T3 from T3a/T3b (sheet 08/21). Spar W4 from W4a/W4b (sheet 11/21). Trailing Edge TE1 from TE1a/TE1b (located on sheet 10/21). Spar Cap S3 from S3a/S3b and S5 from S5a/S5b (sheet 08/21). Spar Web S1 from S1a/S1b (sheet 01/21). Wing center top section sheeting W6 from W6a/W6b (sheet 02/21). Use a straight edge to align parts as you glue together along the scarf and finger joints.

T1b

T2b

T3b

TE1b

S5b

S1b

S3b

W4bW4a

T1a

T2a

T3a

W6a

W6b

TE1a

S5a

S1a

S3a

T3

T2

T1

W4

TE1

S5

S1

S3

W6

2. Fit S1 spar (assembled in step 1) centered atop S3 lower spar cap (assembled in step 1) align at tab and notch

locations, square, then tack glue together by placing a small drop of thin CA glue at each tab and notch.

3. Locate the 1/8 in. ribs marked R1 (sheet 11/12) dry fit (do not glue) these to notches located in S1 spar web on either side of the center finger joint.


4. Dry fit the 1/32 in. plywood servo tray W1a (sheet 19/21) to the wing center section spanning S1 spar web and ribs R1. Double W1a by fitting 3/32 in. balsa lower center section sheeting W1b (sheet 07/21) as illustrated below. Square the center section against the spar and your flat work surface. Retain parts by tack gluing with thin CA at tab and notch locations and where the W1b sheeting joins the lower spar cap.

***Optional*** If you plan to install the optional spoiler assembly, remove the center section servo knock-out plug by cutting it free with a sharp hobby knife as illustrated.

5. Locate ribs R2 (sheet 06/21) and key to assembly as illustrated below. Use the plan set to reference proper rib placement.

6. From one 48 in. length of the provided carbon fiber flat stock cut two 18-1/4 in. in lengths.


7. Dry fit one of the two 18-1/4 in. lengths of carbon stock cut in the previous step through the lower set of notches just forward of the S1 spar web in ribs R2 and R1.

Carbon flat stock spar spans the wing center section from the inside edge of the right sub rib R2b to the left sub-rib R2b. Fit the sub ribs R2b (sheet 03/21) to the wing assembly to assist with centering the carbon flat stock spar. If the flat stock spar is a bit long remove from assembly, trim, and re-install.

8. With the lower carbon flat stock installed fill in the remaining sub ribs R1a, R1b, and R2a (sheet 02/21) to both right and left side of wing assembly. Square sub ribs to wing spar, and wing to your flat building board, then retain with a drop of CA glue at each tab and notch location. Place an additional drop of CA glue at each point where a rib or sub rib makes contact with the carbon flat stock.


9. Dry fit the second 18-1/4 in. length of carbon flat stock spar to the upper set of notches forward of the spar web

spanning ribs R1 through R2b. Remove, trim, and re-install as required to fit carbon properly. Square assembly to building board and make certain that carbon strip is completely seated within notched portion of rib (the strip will seat flush with the top edge of the center spar cap). Retain strip by placing a drop of thin CA glue at each point where the carbon spar passes through the notched rib.

10. Fit 3/32 in. balsa ribs R3 and R4 (sheet 06/21) and 1/16 in. balsa sub ribs R3a, R3b, and R4a (sheet2/21) to wing assembly as illustrated below. Use the plan set as a guide for proper rib placement. Square ribs to wing spar and flat building board then retain by tack gluing at tab and notch locations. Note that R4b is not installed in this step and will be dealt with later in the assembly.

11. Install upper spar cap S5 (previously assembled in step 1) to wing assembly as illustrated below. Retain part by tack gluing at tab and notch locations.


12. Join the 1/8 in. trailing edge (previously assembled in step 1) to the wing assembly as illustrated below. The

finger joint of TE1 should center between right and left ribs R1. Verify that each rib is fully seated within the corresponding notch at trailing edge and retain trailing edge by tack gluing at tab and notch locations.

13. Locate the 3/32 in. balsa W2 wing trussed sub ribs (sheet 07/21) and install to assembly between the right and left rib bays formed by R1/R2 and R2/R3 as illustrated below.

Next locate the 3/32 in. balsa W3 wing trussed sub ribs (sheet 07/21) and install to assembly between the right and left rib bays formed by R3/R4 and R4 and end of wing as illustrated below.

With the trussed sub ribs installed to both right and left sides of the wing assembly, square wing to flat work surface and tack glue at tab and notch locations and the interface of trussed sub ribs to the back side of the wing spar.


14. Create center section dihedral break rib R5 by laminating 1/32 in. ply outer rib facing R5a (sheet 19/21) to 3/32

in. balsa rib R5 (sheet 06/21). It is strongly suggested that you lay the parts out MIRRORED to one another, as illustrated below, to create a right and left R5 rib assembly. Register the parts to one another matching at notched locations you may also use a 3/16 in. and/or 1/8 in. drill bit to register parts where they have been drilled by the laser. Use a medium CA glue to give yourself ample working time to register and bond parts. Note: The R5 assembly needs to be perfectly straight to properly mate to the wing tips – when laminating these parts you should work on top of a flat work surface.

With the 1/32 in. ply facing to the OUTSIDE, fit the completed R5 rib assembly to the left and right of the wing center section as illustrated below. Stand your wing up on end and seat R5 completely against the angled edge of the spar web and trailing edge. Now make certain that R5 is flat against your work table and bond R5 with CA glue where it makes contact with the notched trailing edge and the spar.

15. Locate the 1/16 in. ply tip spar pocket S8 (sheet 20/21) and fit to FORWARD surface of spar web between rib R4a and R5 as illustrated below. The outer edges of S8 must fit flush against ribs and spar caps. Once satisfied with the fit bond with thin or medium CA glue. Note: don’t make a mess of the glue job here as globs of glue along the inside edge of S8 will cause fit issues when installing the Delrin tip spars.


16. Enclose the tip spar pocket by laminating the 1/16 in balsa webbing S9 (sheet 04/21) spanning sub rib R4a and

rib R5 as illustrated below. Note: it may be helpful to lightly sand the edges of this part (just enough to remove the laser burn) then bond with medium CA glue. Attempt to apply glue sparingly to the forward surface of the S8 plywood pocket to minimize any glue that may squeeze out inside the tip spar pocket and cause fit issues with the tip spar.

With the S9 webbing installed complete the step by installing sub rib R4b (sheet 02/21) to notches in webbing. Retain with a drop of CA glue at tab and notch locations.

17. Install 3/32 in. part W6 (07/21) to wing assembly as illustrated below. IMPORTANT to avoid warping the outer rib R5 it is strongly suggested that you stand the wing on end with R5 completely supported against your FLAT work surface while bonding W6 to the assembly.

18. Install 1/8 in. balsa parts LE1 (sheet 11/21) to the right and left INSIDE surface of ribs R1. Align parts using the notches and seat fully against spar.

19. The carbon wing spars should now be thoroughly bonded to the wing assembly. Lay the wing assembly flat on top of your work surface and wick thin CA glue along the entire length of the upper and lower carbon strip wing spars.


20. Install the center section 1/16 in. balsa shear webbing SW1 (sheet 04/21). Bond using medium CA between the sheer web and carbon spar, then build up a glue fillet between the sheer web outer edge where it contacts ribs and spar caps.

Follow the same procedure for installing the right and left shear web components SW2, SW3, SW4 and SW5 (sheet 04/21). Reference plan set for proper part location.

21. Dry fit forward 3/32 in. turbulator T1 (assembled in step 1) to assembly as illustrated below. Note that T1 is notched and cut to fit only in the leading most set of notches along rib and sub ribs. Additionally, all turbulators T1, T2, and T3 are designed to fit flush with the inside R1 ribs and outside R5 ribs, however, at mid span from ribs R1a through R4b the turbulators will sit proud of top surface of rib by 1/16 in. Use a piece of scrap balsa to reference proper height.

IMPORTANT! Once T1 turbulator has been fit to the wing assembly bond with thin CA glue starting at rib R1 and working out to sub rib R4b. PRIOR TO BONDING TURBULATOR TO R5 READ THIS: Do not attempt to use notching in T1 turbulator to set proper spacing for R5. As every wing will build with some variance and we don’t want to blindly bond this part and possibly warp R5. As previously stated, R5 must remain perfectly FLAT to match the wing tip. Thus, stand the wing assembly on end supporting R5 against your flat work surface, make certain that R5 is indeed flat to the work surface, allowing turbulator to float within notch at R5 to achieve a perfectly flat and warp free R5, once satisfied that R5’s flat bond the turbulator to the R5 end rib.


Continue installing turbulators T2 and T3 (assembled in step 1) use the same technique as outlined above, however, T2 and T3 are not notched to set rib spacing.

22. Install the 1/8 in. balsa center section leading edge parts LE2 (sheet 10/21). There are two each of LE2 install one spanning right and left ribs R1. Install the second by laminating on top of the first to double the thickness of this part. See illustrations below.

23. Lay in the leading edge which is composed of ¼ in. square balsa stock. Start the balsa stock at R1 and allow it to extend beyond rib R5. Bond using thin CA glue. Trim and sand balsa stock flush with outer surface of wing panel at R5. Repeat for opposite side of wing.

24. Use the remaining carbon flat stock from step 6 and trim to 11 in. length.


25. Install 11 in. length of carbon flat stock to recess in wing trailing edge centered between right and left ribs R2 as

illustrated below. Bond carbon flat stock using medium CA glue.

26. Install the sub spar W4 (assembled in step 1) reference photos and plan set for proper positioning. Tip: It is suggested that you reduce the size of this part by sanding prior to installation. Due to variance in wood thickness from the mill and the precision of the laser you may find the fit of this part to be quite snug. We suggest reducing the thickness and height of part by sanding. First sand the top and bottom of sub spar (just enough to remove the laser burn) then rotate and sand either side. A good indication of when to stop sanding is to attempt sliding the sub spar in through provided hole in the plywood faced outside rib R5. If it’s snug here you’ll risk breaking ribs as you snake the part through the assembly. Reduce the size of the part to ease install and use a gap filling medium CA to bond.

27. Locate spoiler frame 1/8 in. balsa part SP1 (sheet 10/21) Remove, and set aside for later, the spoilerSP2 from the center of part SP1. The spoiler frame features a series of tabs that will key into the spar cap strip and a series of notches that capture key ribs along the wing assembly. Fit SP1 to wing assembly at back-side of top spar cap strip spanning left and right ribs R3. Bond spoiler frame along length of spar cap strip. Wrap spoiler frame down across wing and key to ribs R2 and R3 bond with thin CA glue where spoiler frame meets ribs R1, R2, and R3 and trussed sub ribs W2. See illustration below and plan set for positioning.


28. Install W6 center section sheeting (assembled from W6a and W6b in step 1) as illustrated below. Bond with medium CA glue.

Sand the center section sheeting to match contour of rib and taper into trailing edge as illustrated below.

29. FINAL GLUE THE WING. In many of these steps we’ve simply tack glued parts using only a small drop to hold the assembly together while additional parts are installed. Now is the time to revisit all of these joints and thoroughly bond the wing. Lay the wing flat on top of your building board and revisit all joints previously tack glued with thin CA glue. Apply a gap filling medium CA glue to all off-angle joints such as those found where W2 and W3 meet ribs and spar webs and where R5 meets the trailing edge of the wing.

30. FINAL SAND THE WING. In preparation for covering lightly sand the wing with 400 to 600 grit paper. Use a razor plane, sanding bar, sanding block, or some combination thereof to round the leading edge to match that of the airfoil profile. You may use the wing saddle of the fuselage to verify the fit. Just as the turbulators sit proud above the inner wing ribs and flush with the outer wing ribs so does the leading edge. Use your 1/16 in. balsa scrap to verify that you’ve set the proper height of the leading edge relative to the top surface of the interior wing ribs R1a through R4b.

Proceed to cover the wing only after completing the wing tip assembly and the joining of the wing tip procedures outlined next in this manual.


Wing Tips Build right and left wing tips mirrored on the building board and in tandem to prevent building two of the same side.

1. Begin wing tips by locating the 1/16 in. balsa spar web S2 (sheet 04/21) and 1/16 in. lower spar cap strip S4 (sheet 04/21). Orient parts identical to photo below (mirrored and in tandem) then tack glue at tab and notch locations.

2. Key ribs R7, R8, R9, and R10 to spar as illustrated below (sheet 03/21). Verify that ribs are properly seated to spar web and square then tack glue with thin CA.

3. Key 1/8 in balsa trailing edge TE2 (sheet 09/21) to wing tip assembly and secure by tack gluing at notch locations where ribs interface with trailing edge.


4. Join 1/8 in. balsa end rib R11 (sheet 09/21) to both right and left wing tip assemblies as illustrated below. Tack glue using thin CA glue.

5. Fit 1/8 in. balsa wing tip W7 (sheet 09/21 and 11/21) to assembly as illustrated. W7 tabs to R11 end rib and fits flush against wing trailing edge TE2 to square wing tip assembly.

6. Fit the 1/16 in. balsa upper spar cap S6 (sheet 04/21) to wing tip assembly and tack glue at tab and notch locations.

7. Create wing dihedral break rib R6 by laminating 1/32 in. ply outer rib facing R6a (sheet 19/21) to 3/32 in. balsa rib R6 (sheet 05/21). Follow assembly method detailed in step 14 of Wing Center Section assembly.


8. Join R6 dihedral break rib assembly with 1/32 in. ply face facing outside of assembly. Fit R6 to angle of spar web then stand wing tip assembly on end and flatten R6 to work surface prior to bonding with thin CA glue.

9. Locate the 1/16 in. ply tip spar pocket S10 (sheet 20/21) and fit to FORWARD surface of spar web between rib R6 and R7 as illustrated below. The outer edges of S10 must fit flush against ribs and spar caps. Once satisfied with the fit bond with thin or medium CA glue. Note: don’t make a mess of the glue job here as globs of glue along the inside edge of S9 will cause fit issues when installing the Delrin tip spars.

10. Enclose the tip spar pocket by laminating the 1/16 in balsa webbing S11 (sheet 04/21) spanning rib R6 and rib R7 as illustrated below. Note: it may be helpful to lightly sand the edges of this part (just enough to remove the laser burn) then bond with medium CA glue. Attempt to apply glue sparingly to the forward surface of the S10 plywood pocket to minimize any glue that may squeeze out inside the tip spar pocket and cause fit issues with the tip spar.


11. Install 3/32 in. balsa part W6 (07/21) to wing assembly as illustrated below. IMPORTANT to avoid warping the outer rib R6 it is strongly suggested that you stand the wing on end with R6 completely supported against your FLAT work surface while bonding W6 to the assembly.

12. Install 1/16 in. balsa sub ribs R6b, R7a, R8a, R9a, and R10a (sheet 03/21) to wing tip assemblies as illustrated below. Tack glue at tab and notch locations from back side of spar web.

13. Dry fit forward 3/32 in. balsa turbulator T4 to assembly as illustrated below. T4 is marked with an “<-“ which defines the end that should be placed closest to the dihedral break rib R6. As with the wing center section assembly all turbulators T4, T5, and T6 are designed to fit flush with the inside R6 ribs and outside R11 ribs, however, at mid span from ribs R6b through R10a the turbulators will sit proud of top surface of rib by 1/16 in. Use a piece of scrap balsa to reference proper height.

IMPORTANT! Once T4 turbulator has been fit to the wing assembly bond with thin CA glue starting at rib R11 and working in to sub rib R6b. PRIOR TO BONDING TURBULATOR T4 TO R6 READ THIS: Do not attempt to use notching in T4 turbulator to set proper spacing for R6. As every wing will build with some variance and we don’t want to blindly bond this part and possibly warp R6. R6 must remain perfectly FLAT to match the dihedral break rib R5 of the wing center section. Thus, stand the wing assembly on end supporting R6 against your flat work surface, make certain that R6 is indeed flat to the work surface, allowing turbulator to float within notch at R6 to achieve a perfectly flat and warp free R6, once satisfied that R6’s flat bond the turbulator to the R6 end rib.


14. Install the remaining 3/32 in. balsa turbulators T5 and T6 (sheet 05/21) and fit / tack glue to the wing tip assembly in their respective positions.

15. The turbulators have been slightly oversized to allow for variance in wing assembly. Trim excess turbulator stock as it extends beyond ribs R6 and R11, then sand flush with outside surface of rib.

16. Locate and fit/sand 1/8 in. balsa sub spar W5 (sheet 09/21) to fit notches within ribs of wing tip assembly and install to wing tip spanning ribs R6 through R11 as illustrated below. Note: as with the turbulator stock in previous steps W5 features an “<-“ to designate which end has been cut to match the angle of the dihedral break rib R6.


17. Install the provided ¼ in. square balsa stock to the notches at the leading edge of the wing tip ribs. Retain with thin CA glue.

Trim and sand flush the ¼ in. square balsa stock where it overhangs rib R6.

18. Locate the 1/8 in. balsa cross grain wing tip doublers W8 (sheet 11/21) there are four of these. Match and bond using medium CA glue two each of part W8 to both the right and left wing tips on both sides of the W7 wing tip. Complete the wing tip by sanding W8 and the wing tip round.

19. FINAL GLUE THE WING TIP. In many of these steps we’ve simply tack glued parts using only a small drop to hold the assembly together while additional parts are installed. Now is the time to revisit all of these joints and thoroughly bond the wing. Lay the wing flat on top of your building board and revisit all joints previously tack glued with thin CA glue. Apply a gap filling medium CA glue to all off-angle joints such as those found where R6 meets the trailing edge of the wing tip.

20. FINAL SAND THE WING TIP. In preparation for covering lightly sand the wing tip with 400 to 600 grit paper. Use a razor plane, sanding bar, sanding block, or some combination thereof to round the leading edge to match that of the airfoil profile. You may use the wing saddle of the fuselage to verify the fit. Just as the turbulators sit proud above the inner wing ribs and flush with the outer wing ribs so does the leading edge. Use your 1/16 in. balsa scrap to verify that you’ve set the proper height of the leading edge relative to the top surface of the interior wing ribs R6b through R10a.


Joining the Wing Tips Method: Wing tips are joined to the center wing section using a robust Delrin tip spar, double anti rotation dowels, and four sets of incredibly strong Neo. Magnets. This arrangement negates the need to tape your wing tips on as they are neatly retained by the friction of the tip spar and attractive force of the Neo. Magnets.

1. Separate the provided Delrin tip spars. Tip spars are marked “RIGHT” and “LEFT” though they are identical you may be required to make fit adjustments to fine tune each tip spar to properly seat within your wing center section and wing tip. The “RIGHT” and “LEFT” designation is to help you identify the placement of these custom fit parts. Fit tip spars to your wing center section assembly and corresponding wing tip by lightly sanding the top and bottom edges (to remove the tooling marks from cutting) then more aggressively reduce the thickness of tip spar until they slide easily within wing tip. This takes some time to get right but it’s well worth it. You absolutely do not want the fit to be overly snug as this will make it next to impossible to separate the panels.

2. Build the wing dowel jig from 1/8 in. balsa parts (sheet 10/21) as illustrated below.

3. Use the plan set as a reference for proper positioning of the wing anti-rotation dowels. You will install one each to either side of the wing center section and the wing tip. These dowels are composed of 1/8 in. aluminum tubing and are located in your 2x3 hardware bag. Use the previously assembled jig to obtain the proper extension and maintain perpendicular orientation of the dowel to rib surface.


4. With the wing anti-rotation dowels installed, locate the receiving hole for the dowel in both the wing tip and wing center section. Ream the receiving hole with a 1/8 in. drill bit until the dowel slide easily into the receiving hole.

5. Clean up the large laser drilled holes in both the wing tip and wing center section dihedral break ribs R5 and R6 using a 3/16 in. drill bit. Use the plan set as a guide for location and installation of the 3/16 in. diameter Neo. Magnets and balsa plugs.

First install the balsa plug and neo magnets to the wing tip. Neo. Magnets should be installed so that they are flush and exposed to the outside surface of the R6 wing tip rib. Retain magnets using medium CA on inside of hole followed by wicking thin CA glue around the perimeter of the magnet.


6. Magnets are polarized and will attract in one direction but repel in the other. We need to use the attractive force

of the magnets to retain our wing tip. To properly match the polarity of the wing tip magnet to the wing center section magnets do the following: Locate the two 3/16 in. Neo. Magnets which you will be installing to the wing center section. Prior to installing these magnets allow them to “snap” themselves to the outside edge of the magnets you just installed to the wing tip. While the, soon to be installed, wing center section magnet is clinging to your wing tip magnet; use a permanent marker make a mark on the outside surface of the magnet.

Install this “marked” magnet with the “mark-side” in and the shiny side exposed to the outside surface of the wing center section. Prior to gluing it would be wise to test the magnet polarity just to be certain you got it right. You only get one shot at it and the polarity must be right before you commit these parts with glue. Once satisfied that the polarity is setup for attraction commit the magnets in the wing center section using medium and thin CA glue.

7. Test the fit once more, this time using the Delrin tip spar. Now, prior to covering the wing, is the time to make minor fit adjustments to your anti rotation pin’s and tip spar.


Spoiler and SpoilerSaver™ Assembly Prior to proceeding the wing center section should be completely covered with AeroFILM or AeroFILM Lite. Additionally, covering and balsa plug should be removed from the underside of the wing to expose the spoiler servo mounting pocket. Covering has been removed from the assembly photos simply for clarity. Please note: If you have elected to rubber band on your wing the spoiler cannot be made functional, return to these assembly steps when you’ve built up enough experience and confidence to fly with the bolt-on wing option and wish to make functional the spoiler.

1. Locate the spoiler set aside previously during the wing center section assembly (sheet 10/21) and 1/16 in ply cross grain spoiler doubler SP3 (sheet 20/21). Bond SP3 with medium CA glue to the recesses in either side of SP2 to stiffen the spoiler assembly.

2. The spoiler assembly is etched with the following text “UNDERSIDE TRAILING EDGE BEVEL 45 DEG” along the edge that the spoiler is etched with this text sand a 45 degree bevel using a sanding bar or sanding block. See illustrations below.

3. With the spoiler assembly properly sanded cover spoiler in AeroFILM or AeroFILM Lite. 4. Install 1/16 in. ply spoiler control horn SP4 (sheet 20/21) to the underside (etched) of the spoiler assembly with

the round side facing the beveled edge and the sharp side facing the leading edge as illustrated below. Note that a spare part SP4 has been provided on sheet 20/21.


5. Prepare the HS-56 servo for mounting. Remove the control horn from your HS-56 servo, use your radio or servo tester to center the servo within it’s available travel. Now with the servo laying on it’s side, as illustrated, remove the twin hole mounting tabs (two each) on either side of the servo body. Once finished your servo should retain all three of the single hole mounting tabs spaced around the perimeter of the servo body as illustrated in the second photo of this series.

6. Prepare the spoiler-side EZ-Connector. Provided in the small hardware bag are two DuBro RC Mini EZ Connectors (DUB845). Ream ONLY ONE Mini EZ Connector to 1/16 in leaving the other un-modified.

7. Located in the 4x6 hardware bag find the provided 1/16 in OD aluminum tubing stock rough-cut a length of tubing to 7/8 in (Aluminum tubing is simple to cut by simply rolling the tubing along a flat surface using the edge of a sharp razor blade positioned at the cut point to score the tube which can then be easily snapped) then sand to the final length indicated on the plan set. De-burr the ends of the tube so that a 1/32 in. diameter wire (also provided in the hardware bag) will easily pass through the tube.

Pass the completed and properly sized aluminum tube through the Mini EZ Connector (reamed to accept the tubing in step 6) as illustrated in the second photo below to create the spoiler push tube assembly. Allow the tubing to extend no more than 1/32 in. beyond one side of the Mini EZ Connector. Apply thread locker or CA to set screw of Mini EZ Connector.


8. Mount the completed spoiler push tube assembly (from step 7) to the spoiler control horn exactly as illustrated

below.

9. Tape hinge the spoiler to the wing assembly using ¾ in. wide clear scotch tape or DuBro RC hinge tape. The spoiler should lay freely operate and lay flat within the spoiler pocket. Verify that your spoiler push tube looks similar to the second illustration below.

10. From the HS-56 servo parts package (included with your HS-56 servo) locate the single arm control horn and trim to length as illustrated. The outer most hole in the control arm should be approximately ½ inch from the center of the servo arm.


11. Drill the outer hole to 1/16 in. and install second (un-modified) DuBro RC Mini EZ Connector (DUB845) exactly

as illustrated below.

From the 4x6 hardware bag, locate and cut to ¾ in. length the 1/32 in. music wire. Install the cut wire within EZ Connector as illustrated leaving no more than 1/32 in. extending beyond the connector barrel. Install the completed control horn back on the centered servo output shaft exactly as illustrated below.

12. Mount the HS-56 servo to the underside of the wing nesting the servo side 1/32 in. push rod within the 1/16 in. aluminum spoiler push tube. Use the mounting hardware provided with your HS-56 servo kit to fasten the servo in place. Make certain that the servo control horn aligns on the same side as the spoiler push tube as illustrated below.


13. From the top side of the wing, lift the spoiler just far enough to gain access to the push tube hardware. Loop a small elastic band over the set screw of the spoiler push tube Mini EZ Connector. Then from the underside of the wing use a small pair of needle nose pliers or steal your wife’s crochet hook and loop around set screw of servo side push rod EZ-Connector. Note: The small hair band available at your local drug store work great. We’ve provided a small assortment of mini rubber bands in your kit to get you started. It is recommended to use two of the smaller diameter bands or one of the larger diameter bands doubled up (twist into figure eight and back on itself) to provide proper tensioning for the spoiler servo saver assembly. As this is a fairly new concept in spoiler rigging I’ll have a help/operational video active on the www.stevensaero.com web site linked from this products page.

14. Radio setup thoughts and function test. It’s common in the soaring community to assign your throttle to a switch and the spoiler to the throttle slide. Coming from a power background I find this to be somewhat annoying (not to mention dangerous and potentially damaging to your equipment) and am not willing to sacrifice proportional control of throttle for an on-off switch. Likewise I find that having spoilers set on an on-off switch to be equally annoying. What to do? Certainly computer radios can come to the aide and fix many of these woes. For setup in this manual I’ll assume that the user only has access to a basic 4 channel radio the rest of your radio rich folks can program to suit your individual taste.

Spoiler function on basic 4 ch. radio. Setup your radio as follows to have proportional control over all channels including throttle and spoiler!

Channel on radio Function on Model Throttle Throttle Aileron Rudder (Rudder provides roll control on a 3ch Model) Elevator Elevator Rudder (not used on 3ch model) Spoiler*

*As our SpoilerSaver™ spoiler linkage method allows for 100% over travel in the opposite direction of applied spoiler input you can install this on a simple on off switch or proportional stick control, such as rudder, without worry of over travel destroying your spoiler or servo linkage. Applying spoiler will cause the nose of the model to pitch down. Compensate by applying up elevator. To apply spoiler move rudder stick left or right (depending on servo travel direction) to neutralize spoiler center the rudder stick. With radio setup verify that spoiler is operational and extends to at least 45 degrees with full application of rudder stick. Verify that spoiler completely closes once stick is centered. Adjust linkage, band tension, and or servo centering to fine tune spoiler closed position. Should you be blessed with a computer radio adjust spoiler servo travel to 125% or better to get maximum travel of 60 degrees from your spoiler assembly.


Main Gear 1. Locate the pre-bent 1/8 in. wire landing gear. If necessary, ream the provided foam wheel hubs to roll with

minimal resistance on the 1/8 in. wire stock. Retain wheel to landing gear using one press-fit star washer per side.

2. Cut the provided 3/16 in. diameter hardwood dowel stock to the length indicated on the plan set. Round the edges of the dowel and test fit to fuselage. Retain with CA glue to fuselage AFTER THE FUSELAGE HAS BEEN COVERED. (covering omitted from fuselage in photo series)

3. To retain landing gear to model, center landing gear in slot on underside of fuselage. Loop one end of a #32 rubber band around landing gear lug then pass around through loop in top of landing gear several times. Finally loop free end of rubber band back on lug. Repeat for opposite side. You can change the tension and shock absorption of landing gear by varying the thickness, number of turns, and total rubber band count.


Wing Attachment The default method for wing attachment is through the use of a captured leading edge wing saddle, centering pins, and nylon wing bolts. Optional rubber band attachment may be utilized at the expense of spoiler function. Spoiler may not be made fictional when using rubber band wing attachment. Note: Covering has been omitted from wing assembly photos below. Do not install the following parts until you have completed covering your wing in AeroFILM or AeroFILM Lite.

1. Test fit the 1/16 in. ply wood parts LE3 (sheet 20/21) to the slots in the wing leading edge center section. LE3 is captured both at the leading edge and along the length of the part as it nests into the slots of the doubled center wing ribs. Test fit of wing with LE3 temporarily installed to fuselage assembly and wing saddle. If required, adjust fit of LE3 to wing and fuselage by sanding part. Once satisfied with the fit of these parts glue LE3 into position by wicking thin CA glue within the slots that receive the part.

2. Locate 1/16 in. plywood part W6c wing bolt doubler (sheet 20/21). Cover the top surface of this part with AeroFILM or AeroFILM lite. Leave the bottom of the part natural wood. Center this part as illustrated over the wing center section trailing edge matching the holes in W6c with the holes in the wing center section sheeting. Use a hot, fine tipped, soldering iron or hobby knife to remove a section of covering material from your wing directly beneath where W6c will be installed to expose bare wood. Bond W6c to wing trailing edge using medium CA glue.

For optional rubber band on wing see plan set for proper installation of wing mount lugs.


Final Assembly Notes General information: Final assembly assumes that the builder has some degree of experience finishing ARC/ARF style models and will not be described in agonizing detail. Verify parts fit and hinge method: Prior to covering this model all components should be dry fit together, Pay close attention to the fit of the wing to the wing saddle in the fuselage and the fit of the vertical stabilizer to the fuselage assembly. You must also have prepared your control surfaces based upon the hinge scheme. By far the quickest method for hinging control surfaces is using tape hinges. The plan sheet suggests how to sand the leading edge of the control surfaces in preparation for the tape hinge method. (If you prefer to use CA hinges, we suggest obtaining SIG brand “easy hinges” part SIGSH710. The plan set references suggested “easy hinge” locations, and offers guidance for cutting these to the proper size. The leading edge of all control surfaces must also be adjusted for a center hinge method using two 45 deg. bevels.) Cover the model: Cover all wing and fuselage components using your favorite covering. We recommend using AeroFILM Lite or AeroFILM available from StevensAero.Com. AeroLITE will save about 1.0-1.5 oz. in weight over AeroFILM or heavier covering materials. As covering techniques are beyond the scope of this build manual we suggest visiting the AeroFILM product page at our web site (http://www.stevensaero.com) and reading the AeroFILM covering guide. Where to remove covering: When covering you should remove covering from the lightening hole / wire access hole of former F1 to allow cooling airflow to enter the fuselage. Next, remove covering from the vent hole in the battery access hatch to allow cooling air to exit the fuselage and allow you a finger hold for installation and removal of the hatch. It is not required to remove covering from the vertical stabilizer where it bonds to the fuselage. Hinge control surfaces: Attach control surfaces to the model using the tape hinge method described on the plan set, or with CA hinges if you prefer that option. Install hard points for gear: If you have not done so already, center the 3/16 in. dowel for landing gear retention and secure to the fuselage with thin CA glue. If using rubber band on wings install these dowels as described on the plan set. Installation of tail feathers: Key the vertical stabilizer and rudder to the fuselage. See that the tabs in the vertical stabilizer fit the notches in the fuselage and secure with thin CA glue. Bolt the elevator assembly and tail skid in place as described previously in this manual. Radio and servo installation: Install your receiver and servos. We suggest two (2) Hitec HS-65 or similar servos. Reference the plan sheet for servo locations. Your elevator and rudder servos should be installed in the pre-cut servo pockets within the battery compartment and connected to the Elevator and Rudder using pushrods threaded through the previously installed pushrod housings. With your servos installed, fire up your radio and center all servos. Mechanically center your servo control horns so that they are perpendicular to the servo body. Install the provided Du-Bro EZ-Connectors (DUB845) to the center hole on all servo control arms (you can move this mounting position farther out along the servo control horn for more aggressive surface travel). Du-Bro Micro II (DUB919) two post control horns have been provided in this kit. Ream the control horns to fit the .045” wire push rods and Install these on the same side of the control surface that your push-rod will reside on. Control horns will install into the laser drilled holes in each part. Use the plan sheet as a guide to bend your push/pull rods from the included lengths of 0.045 in. diameter wire stock. Install push/pull rods with the “L” bend placed through the outer most position on control surface horns and retain using the provided Du-Bro Micro2 EZ-Links (DUB920). In the photo series below covering and hinges have been omitted for clarity only as this step anticipates that your surfaces are covered and hinged. It’s a good idea to make a safety keeper for your ez-link so that they do not depart in-flight. Use the plan sheet as a guide and the provided length of fuel tubing to create a safety band for your EZ-Link see the section on the plan set marked “PREVENT IN-FLIGHT FAILURE OF EZ LINKS” Control surface adjustments: Adjust rudder parallel with vertical stabilizer and set position by tightening set screw in EZ-Connector. Adjust elevator parallel with horizontal stabilizer and set position by tightening set screw in EZ-Connector. If using a computer radio set initial low rate control surface throws as follows:

Elevator +/- 20 degrees 30% expo Rudder +/- 30 degrees 30% expo

Non computer radio users should use mechanical means to limit control surface travel to that described above. Cut all push rods down allowing only ½ in. additional length beyond the ez-connector at each servo.


Motor and propeller mounting: Mount the Hacker A20-20L, A30-28S, VSport 280, or E-Flite Park 480 using the radial mounting hardware included with your motor package. Secure the motor to the firewall using the provided four (4) 4-40 x 3/8” machine screws (thread-locking compound on these screws is highly recommended). Proper down thrust is built into the firewall. Four 1/16 in. plywood washers are provided in this kit (sheet 20/21) to shim the left side of the motor (as viewed from the cockpit) to achieve proper right thrust. Place both ply washer under each of the two left side motor mount arms. Right thrust will vary with your power system selection but we have found that with the recommended Hacker A30-28S and 10x5 propeller one 1/16 in. shim is typically about right. To reduce right thrust simply remove the shim and reduce it’s thickness through sanding.

Install your balanced propeller to the motor. Never run a propeller assuming it is in balance without checking it first. Never run a propeller that is known to be damaged, repaired, or out of balance. Never run a motor with a bent shaft. In-flight vibration from out of round and out of balance components will cause pre-mature failure of airframe and electrical components. If you are un-certain how to balance a propeller, seek advice from an experienced hobbyist or your local hobby retailer. Mount the wing: Retain wing to fuselage using the provided 1-1/2 in. nylon mounting bolts. If using the rubber band on wing option. Retain wing to fuselage using four (4) #33 rubber bands two (2) on each side of the fuselage. Use fresh rubber bands prior to each flying session. DO NOT cross the rubber bands, use bands of greater size / thickness, or exceed six (6) rubber bands (three per side) as this will prevent the wing from cleanly departing the fuselage in the event of a crash. Landing gear assembly: Place wheels on the landing gear assembly and retain by forcing the 1/8” star washer wheel retainers over the 1/8” axle. Depending on the wheels provided with your kit you may need to ream the hubs to fit the 1/8 in. axle diameter. Retain landing gear to fuselage using two (2) #33 rubber bands one (1) on each side of the fuselage. Use fresh rubber bands prior to every flying session. Use the method for landing gear attachment as described previously in this text. Battery installation and Center of Gravity: Move battery fore and aft within fuselage to adjust the models Center of Gravity (CG). We suggest locating the CG of the model in the upright position so that the fuselage bottom is level with the horizon when balancing the airframe by a finger tip positioned on the underside of each wing panel 2-3/4 in. aft of the wing leading edge. This initial CG is suitable for your first flights, move CG aft cautiously to enhance soaring capabilities. Lateral model balance: Place a round head pin in the rudder assembly near the bottom of the rudder. With the rudder aligned parallel to the fuselage and vertical stabilizer support the model inverted with one finger on pin head and the other finger on the motor shaft. With the model suspended in this fashion your wing tips should balance level with the horizon. If your model does not balance laterally, add an appropriate amount of weight to the “high” wing tip until model balances. Hint: I use adhesive graphics like contrasting color bars on the underside of my wing to balance the model and aid visibility. Warped structure: Check wing and tail surfaces over carefully looking for signs of twists or warps that will need to be removed prior to flying. In the unlikely event that you have a warped surface, have a partner heat the covering of the surface using a heat gun on low heat setting while you gently apply a corrective twist to the structure opposite the warp. Allow the surface to cool while holding the corrective twist. Release correction and check to see that you were successful. If need be, repeat process until surfaces are straight and true. Pre flight check (perform every flight):

o No visible damage to airframe or covering? o Flight pack batteries charged? o Transmitter batteries fully charged? o Proper model selected on radio? (applies to computer radio) o Range check of radio successful? o Center of gravity set properly (2-3/4 in. from leading edge of wing) o Control rods securely connected? o Fresh rubber bands properly installed on wing and landing gear? o Control surfaces moving proper directions? (don’t just wiggle them, check for proper direction of travel) o Propeller secure? o Clear the propeller and perform run-up. Smooth throttle response with no vibration? o Flying site clear?

Upon successful pre-flight announce your departure and commit aviation!

o Point model into wind smoothly apply power and corrective right rudder. o Model should lift off in about 10-15 feet with application of ¾ throttle. o Climb out smoothly to safe altitude. Trim model for level flight in both pitch and roll axis.


THIS PAGE HAS BEEN PROVIDED TO SCHEME A COLOR SCHEME:

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HeliumMG2 v1.00b 02022010