Aeronaut PEPPER User manual

Order No. 1336/00
aero
naut
aero
naut

PEPPER is a sleek model with a considerable speed range. Building materials are mostly laser-cut balsa and light-ply to achieve a light yet strong
structure, spruce is used to enhance the strength of the wing spars. For electric power choose a 28 mm brushless motor with a power of about 200 W. They
all have a bolt circle diameter of 19/16 which will fit the model´s motor mount.
Construction should be according to the step-by-step instructions provided in this manual. Use the parts
list to identify the included stripwood and hardware. Always check that parts fit perfectly and correct, if
necessary, before you glue. Give glue sufficient time to dry or cure, before you proceed to the next step.
We recommend white glue (if not otherwise noted) for gluing, which offers good strength and low weight.
White glue retains a certain degree of elasticity after the glue has cured and will stand up to any loads
which occur during flying.
Recommended Equipment
ŸBrushless, 28 mm, ca. 1,500 kV, from ca. 200 W
Recommendation: Hacker A20-8XL
ŸESC: 30 to 40 A *
Ÿ3 × micro servo, 24 × 22 × 12 mm
Ÿ3S-LiPo, 2,400 mAh
ŸPropeller ca. 7 x 6“ *
ŸSpinner 38 mm, Order No. 7252/01-04
* compare recommendations with data sheet of motor
1
2
In a first step glue together main spar parts F1 A and F1 B. Use a
straight edge against the spar´s building tabs for proper alignment
and secure with tape.
Assemble the 4-part wing jig, place on a flat building board and
secure with tape.
Insert main spar in wing jig. Glue together centre ribs F2, then
glue ribs F2 to F14 to main spar as shown. Make sure that ribs are
fully seated in main spar and jig.
F1 A
F1 B
F2
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
Tips & Hints
We recommend our PONAL wood
glue, Order No. 7638/10
(225 g bottle)
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Technical Data
Wingspan: ca. 1,220 mm
Length: ca. 950 mm
Weight: from 840 g
Wing area: ca. 21 dm²
Wing loading: from 40 g/dm²
RC-functions: elevator, ailerons, motor control
For building we recommend our
aero-pick modeller´s pins,
Order No. 7855/02
Attention! Make sure you follow
instructions carefully.
Note! Additonal information for
current building step.
Sand off retaining tabs of laser-cut
parts for best results.
Use a sharp modeller´s knife to cut
the tabs. Do not remove parts by
hand to avoid damage!
We recommend our modeller´s
knife, Order No. 8185/00

PEPPER is a sleek model with a considerable speed range. Building materials are mostly laser-cut balsa and light-ply to achieve a light yet strong
structure, spruce is used to enhance the strength of the wing spars. For electric power choose a 28 mm brushless motor with a power of about 200 W. They
all have a bolt circle diameter of 19/16 which will fit the model´s motor mount.
Construction should be according to the step-by-step instructions provided in this manual. Use the parts
list to identify the included stripwood and hardware. Always check that parts fit perfectly and correct, if
necessary, before you glue. Give glue sufficient time to dry or cure, before you proceed to the next step.
We recommend white glue (if not otherwise noted) for gluing, which offers good strength and low weight.
White glue retains a certain degree of elasticity after the glue has cured and will stand up to any loads
which occur during flying.
Recommended Equipment
ŸBrushless, 28 mm, ca. 1,500 kV, from ca. 200 W
Recommendation: Hacker A20-8XL
ŸESC: 30 to 40 A *
Ÿ3 × micro servo, 24 × 22 × 12 mm
Ÿ3S-LiPo, 2,400 mAh
ŸPropeller ca. 7 x 6“ *
ŸSpinner 38 mm, Order No. 7252/01-04
* compare recommendations with data sheet of motor
1
2
In a first step glue together main spar parts F1 A and F1 B. Use a
straight edge against the spar´s building tabs for proper alignment
and secure with tape.
Assemble the 4-part wing jig, place on a flat building board and
secure with tape.
Insert main spar in wing jig. Glue together centre ribs F2, then
glue ribs F2 to F14 to main spar as shown. Make sure that ribs are
fully seated in main spar and jig.
F1 A
F1 B
F2
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
Tips & Hints
We recommend our PONAL wood
glue, Order No. 7638/10
(225 g bottle)
i
Technical Data
Wingspan: ca. 1,220 mm
Length: ca. 950 mm
Weight: from 840 g
Wing area: ca. 21 dm²
Wing loading: from 40 g/dm²
RC-functions: elevator, ailerons, motor control
For building we recommend our
aero-pick modeller´s pins,
Order No. 7855/02
Attention! Make sure you follow
instructions carefully.
Note! Additonal information for
current building step.
Sand off retaining tabs of laser-cut
parts for best results.
Use a sharp modeller´s knife to cut
the tabs. Do not remove parts by
hand to avoid damage!
We recommend our modeller´s
knife, Order No. 8185/00

3
4
At one end only splice leading edge F15 (4×4 mm obechi)
and both spruce spars F16 (5×2 mm spruce) over a length
of ca. 15 mm. Leading edge and spars must have a length
of 1,110 and 1,150 mm, respectively.
Fit and glue in place upper spar F16. Glue leading edge
F15 to front of ribs and secure with pins inserted in wing
jig just in front of leading edge.
Slightly chamfer contact surface of both auxiliary spars
F17 at centre ribs and glue to rear end of ribs.
Note: Place large cut-out of F17 at wing centre.
Glue riblets F2 A to either side of centre ribs and secure
with small clamps. Then glue reinforcement F18 for wing
retaining screw to ribs and auxiliary spars.
5
6
Glue together upper (F19 + F20) and lower (F21 + F22) wing
sheeting and place on a flat surface. Immediately remove any
excessive glue and secure with tape until dry.
Glue in place upper wing sheeting of each wing half in two steps.
Slightly chamfer front edge of upper wing sheeting for proper fit at
leading edge. Apply glue to contact surface of leading edge and
the first 5 mm of ribs. Fit upper wing sheeting in place on leading
edge and secure with tape. Leave to dry.
Apply glue to top of ribs (with the exception of centre ribs!), to
upper spruce spar and to auxiliary spar. Slightly press on wing
sheeting and secure with pins and tape. Make sure that wing
sheeting is in good contact with ribs.
Repeat for opposite wing half. When glue has dried, remove wing
from jig, turn upside down and from the inside apply glue to wing
sheeting at centre rib position. Replace wing in jig and secure
wing sheeting with pins and tape at centre rib position.
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F15
F15 F16
F16
F17
F18
F19
F20
F22
F21
F2 A

3
4
At one end only splice leading edge F15 (4×4 mm obechi)
and both spruce spars F16 (5×2 mm spruce) over a length
of ca. 15 mm. Leading edge and spars must have a length
of 1,110 and 1,150 mm, respectively.
Fit and glue in place upper spar F16. Glue leading edge
F15 to front of ribs and secure with pins inserted in wing
jig just in front of leading edge.
Slightly chamfer contact surface of both auxiliary spars
F17 at centre ribs and glue to rear end of ribs.
Note: Place large cut-out of F17 at wing centre.
Glue riblets F2 A to either side of centre ribs and secure
with small clamps. Then glue reinforcement F18 for wing
retaining screw to ribs and auxiliary spars.
5
6
Glue together upper (F19 + F20) and lower (F21 + F22) wing
sheeting and place on a flat surface. Immediately remove any
excessive glue and secure with tape until dry.
Glue in place upper wing sheeting of each wing half in two steps.
Slightly chamfer front edge of upper wing sheeting for proper fit at
leading edge. Apply glue to contact surface of leading edge and
the first 5 mm of ribs. Fit upper wing sheeting in place on leading
edge and secure with tape. Leave to dry.
Apply glue to top of ribs (with the exception of centre ribs!), to
upper spruce spar and to auxiliary spar. Slightly press on wing
sheeting and secure with pins and tape. Make sure that wing
sheeting is in good contact with ribs.
Repeat for opposite wing half. When glue has dried, remove wing
from jig, turn upside down and from the inside apply glue to wing
sheeting at centre rib position. Replace wing in jig and secure
wing sheeting with pins and tape at centre rib position.
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F15
F15 F16
F16
F17
F18
F19
F20
F22
F21
F2 A

79
810
Remove wing from jig and turn upside down. Break off
building tabs and sand lightly to achieve a smooth
contact surface on main spar and ribs.
Install servo leads in wing and secure with tape in servo bay.
Route opposite end of servo leads through hole in lower wing
sheeting and glue wing sheeting in place.
Use same proceedrue as with upper wing sheeting.
Glue in place lower spruce spar F16 and servo frames
F23.
From trailing edge triangular stock (8×40 mm) cut off
two ca. 25 mm long pieces F24, then fit and glue in
place next to centre ribs as shown.
Carefully sand flush rear edge of wing.
Cut off one ca. 80 mm long piece of either trailing edge
triangular stock F25 (8×30 mm) and glue to wing tip as
shown. Make sure that projection of end rib meets with
rear edge of trailing edge profile.
See also following building step.
F16
F23
F23
F24
F24
F24
F25

79
810
Remove wing from jig and turn upside down. Break off
building tabs and sand lightly to achieve a smooth
contact surface on main spar and ribs.
Install servo leads in wing and secure with tape in servo bay.
Route opposite end of servo leads through hole in lower wing
sheeting and glue wing sheeting in place.
Use same proceedrue as with upper wing sheeting.
Glue in place lower spruce spar F16 and servo frames
F23.
From trailing edge triangular stock (8×40 mm) cut off
two ca. 25 mm long pieces F24, then fit and glue in
place next to centre ribs as shown.
Carefully sand flush rear edge of wing.
Cut off one ca. 80 mm long piece of either trailing edge
triangular stock F25 (8×30 mm) and glue to wing tip as
shown. Make sure that projection of end rib meets with
rear edge of trailing edge profile.
See also following building step.
F16
F23
F23
F24
F24
F24
F25

11 13
12 14
Cut off spars, leading and trailing edges at end ribs and
carefully sand flush with contact surfaces of end ribs. Glue
in place wing tips F26 (balsa triangular stock, 20×20 mm)
on end rib and secure with pins.
Glue together aileron servo mounts from 4 pieces F27
each. Align servo with servo arm centred in slot of servo
tray F28, hold in place and glue servo mounts in place
with a drop of medium CA.
Insert servo in servo mounts and install servo tray in wing.
Drill servo frame F23 with 1.5 mm and temporarily install
screws F31.
Note: Servo is held in place by servo mounts. No glue
required.
When dry, sand wing tips and leading edge to shape and
give wing a smooth surface.
Note: Wing tips are shaped automatically when upper and
lower wing sheeting are sanded to a smooth finish with a
sanding bar.
Finally lightly chamfer edges of wing tips.
Bevel front edge of ailerons F29 (trailing edge triangular
stock 8×30 mm) and temporarily attach to wing with
tape.
Mark position of control horn F30 on aileron and cut slot
with razor saw or file into aileron. Glue control horn in
place after covering.
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F26
F27
F28
F29
F30

11 13
12 14
Cut off spars, leading and trailing edges at end ribs and
carefully sand flush with contact surfaces of end ribs. Glue
in place wing tips F26 (balsa triangular stock, 20×20 mm)
on end rib and secure with pins.
Glue together aileron servo mounts from 4 pieces F27
each. Align servo with servo arm centred in slot of servo
tray F28, hold in place and glue servo mounts in place
with a drop of medium CA.
Insert servo in servo mounts and install servo tray in wing.
Drill servo frame F23 with 1.5 mm and temporarily install
screws F31.
Note: Servo is held in place by servo mounts. No glue
required.
When dry, sand wing tips and leading edge to shape and
give wing a smooth surface.
Note: Wing tips are shaped automatically when upper and
lower wing sheeting are sanded to a smooth finish with a
sanding bar.
Finally lightly chamfer edges of wing tips.
Bevel front edge of ailerons F29 (trailing edge triangular
stock 8×30 mm) and temporarily attach to wing with
tape.
Mark position of control horn F30 on aileron and cut slot
with razor saw or file into aileron. Glue control horn in
place after covering.
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F26
F27
F28
F29
F30

15 18
19
17
16
Glue former R5 at right angles into servo tray R4
and glue former R8 at right angles into R7.
Check with set square or similar.
Glue reinforcements for tailplane slot R13 and R14 to
fuselage side. Temporarily insert former R11 into fuselage
side as an end stop.
Cut off two 375 mm and two 225 mm long pieces of 8×8 mm
triangular stock R15.
Place triangular stock on building board as shown and use a razor saw
to make cuts at intervals of 15 to 20 mm over a length of 200 mm.
This will make the triangular stock easier to bend when you glue it to
the fuselage side.
Place right fuselage side R1 A on flat
building board and secure with pins.
Insert former R2 and assembly R3, R4, R5
in fuselage side. Do not glue!
Glue in place wing saddle R12 and make
sure contour matches contour of fuselage
side perfectly. Remove any excessive glue
from slot in R12.
Glue servo tray into former R3 at
right angles.
R5
R4
R3
R13
R14
R15
R11
R8
R7
R2
R12
R3, R4, R5
R1 A

15 18
19
17
16
Glue former R5 at right angles into servo tray R4
and glue former R8 at right angles into R7.
Check with set square or similar.
Glue reinforcements for tailplane slot R13 and R14 to
fuselage side. Temporarily insert former R11 into fuselage
side as an end stop.
Cut off two 375 mm and two 225 mm long pieces of 8×8 mm
triangular stock R15.
Place triangular stock on building board as shown and use a razor saw
to make cuts at intervals of 15 to 20 mm over a length of 200 mm.
This will make the triangular stock easier to bend when you glue it to
the fuselage side.
Place right fuselage side R1 A on flat
building board and secure with pins.
Insert former R2 and assembly R3, R4, R5
in fuselage side. Do not glue!
Glue in place wing saddle R12 and make
sure contour matches contour of fuselage
side perfectly. Remove any excessive glue
from slot in R12.
Glue servo tray into former R3 at
right angles.
R5
R4
R3
R13
R14
R15
R11
R8
R7
R2
R12
R3, R4, R5
R1 A

20 22
21
23
Glue triangular stock R15 on fuselage side along
top and bottom contours as shown and secure
with pins.
Note: Bottom strip ends in front of former R3.
Glue in place canopy frame R17 on fuselage side
along canopy cut-out.
Remove any formers/assemblies from right
fuselage side and build up left fuselage side R1 B
accordingly.
Cut to length four pieces of 6×6 mm
triangular stock R16 for top and bottom
rear fuselage contours.
Temporarily insert formers R9 and R10
into right fuselage side, glue triangular
stock in place and secure with pins.
Remove formers R9, R10, R11.
Glue former R2 as well as assembly R3, R4, R5 in
place on right fuselage side.
Note: R2 is at right angles on fuselage side.
Glue in place battery tray R6, insert and glue wing
retainer R18 in slot in R12.
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R3
R15
R15
R16
R9
R10
R11
R16
R17
R2
R6
R18
R3, R4, R5
R12

20 22
21
23
Glue triangular stock R15 on fuselage side along
top and bottom contours as shown and secure
with pins.
Note: Bottom strip ends in front of former R3.
Glue in place canopy frame R17 on fuselage side
along canopy cut-out.
Remove any formers/assemblies from right
fuselage side and build up left fuselage side R1 B
accordingly.
Cut to length four pieces of 6×6 mm
triangular stock R16 for top and bottom
rear fuselage contours.
Temporarily insert formers R9 and R10
into right fuselage side, glue triangular
stock in place and secure with pins.
Remove formers R9, R10, R11.
Glue former R2 as well as assembly R3, R4, R5 in
place on right fuselage side.
Note: R2 is at right angles on fuselage side.
Glue in place battery tray R6, insert and glue wing
retainer R18 in slot in R12.
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R3
R15
R15
R16
R9
R10
R11
R16
R17
R2
R6
R18
R3, R4, R5
R12

24 26
25 27
Make sure that left fuselage side R1 B fits perfectly on formers
before you glue. Make corrections as necessary.
Then glue in place left fuselage side on formers and glue R19
onto wing retainer R18.
Glue in place formers R9 and R10. Please note that bores for
elevator control are located in upper half of formers.
Secure with tape wrapped around fuselage.
Glue former R11 into rear of fuselage (bore for elevator control
faces up), glue together rear end of fuselage sides without
sanding reinforcements R13, R14. Secure with clamps.
Note: Width at rear end of fuselage must not be reduced.
Elevator control exits between fuselage sides.
Insert and glue R7/R8 into nose section, pulling together front of
fuselage sides. Glue in place motor mount R20 and secure with
clamps and tape.
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R19
R1 B
R18
R11
R9
R10
R20
R7/R8

24 26
25 27
Make sure that left fuselage side R1 B fits perfectly on formers
before you glue. Make corrections as necessary.
Then glue in place left fuselage side on formers and glue R19
onto wing retainer R18.
Glue in place formers R9 and R10. Please note that bores for
elevator control are located in upper half of formers.
Secure with tape wrapped around fuselage.
Glue former R11 into rear of fuselage (bore for elevator control
faces up), glue together rear end of fuselage sides without
sanding reinforcements R13, R14. Secure with clamps.
Note: Width at rear end of fuselage must not be reduced.
Elevator control exits between fuselage sides.
Insert and glue R7/R8 into nose section, pulling together front of
fuselage sides. Glue in place motor mount R20 and secure with
clamps and tape.
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R19
R1 B
R18
R11
R9
R10
R20
R7/R8

28
29
Cut snake outer R21 to a length of 485 mm and glue into
formers with 5 minute epoxy, so that it protrudes 30 mm from
former R3 and 45 mm from former R11.
Carefully sand top and bottom contact surfaces of fuselage, then
glue in place fuselage sheeting.
Upper and lower nose section sheeting consists of three pieces
each (R22 to R24 and R25 to R27) of 3 mm balsa. Upper rear
fuselage sheeting R 28 is one-piece, lower sheeting consists of
parts R29 and tail skid retainer R50.
Note: Glue in place tail skid
R51 after covering.
30
31
Cut off sheeting material and triangular stock and sand flush with
motor mount. Glue in place motor mount cover R30 (1.5 mm
birch ply). Make sure bores in R19 match bores in motor mount
perfectly.
When glue has dried, sand fuselage to shape and round off edges.
With a razor saw cut out canopy and remove from fuselage. Sand
contact surfaces until canopy rests on fuselage without binding.
R21
R22
R23
R24
R25 R26
R27
R28
R29
R50
R3
R11
R30
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28
29
Cut snake outer R21 to a length of 485 mm and glue into
formers with 5 minute epoxy, so that it protrudes 30 mm from
former R3 and 45 mm from former R11.
Carefully sand top and bottom contact surfaces of fuselage, then
glue in place fuselage sheeting.
Upper and lower nose section sheeting consists of three pieces
each (R22 to R24 and R25 to R27) of 3 mm balsa. Upper rear
fuselage sheeting R 28 is one-piece, lower sheeting consists of
parts R29 and tail skid retainer R50.
Note: Glue in place tail skid
R51 after covering.
30
31
Cut off sheeting material and triangular stock and sand flush with
motor mount. Glue in place motor mount cover R30 (1.5 mm
birch ply). Make sure bores in R19 match bores in motor mount
perfectly.
When glue has dried, sand fuselage to shape and round off edges.
With a razor saw cut out canopy and remove from fuselage. Sand
contact surfaces until canopy rests on fuselage without binding.
R21
R22
R23
R24
R25 R26
R27
R28
R29
R50
R3
R11
R30
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32
33
Fit wing into wing saddle and align with centre of fuselage.
Through bore in former R2 mark position of wing dowel, then
drill with 4 mm.
Insert wing dowel F32 in wing and slide wing in place on
fuselage. Make sure wing and dowel fit perfectly and without
binding.
Correct, if necessary, then glue dowel in place.
Position wing on fuselage and align with centre line.
12 mm from the rear of the wing drill with 4 mm through centre
of wing and into R18/R19. Drill through R18/R19 with 5 mm and
from below epoxy in place retaining nut R31.
34
35
Fit canopy former R32 in place in fuselage. To achieve best
results, bevel off contact surfaces with upper sheeting,
triangular stock and canopy frame.
From behind glue magnet R33 and retainer R34 to former
(epoxy), then glue former R32 in place and secure with clamps.
Fit canopy former R35 in place in rear end of canopy. To achieve best results
bevel off contact surfaces with upper sheeting and triangular stock.
From behind glue magnet R33 and retainer R34 to former (epoxy), then glue
former R35 in place and secure with clamps.
Attention: Make sure you check polarity of magnets before you glue!
At front end of canopy glue in place former R36 and retaining tab R37 and
secure with clamps.
Note: Fuselage turned upside
down for clarity.
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F32
R31
R32
R35
R36
R37
R33
R33
R34
R34

32
33
Fit wing into wing saddle and align with centre of fuselage.
Through bore in former R2 mark position of wing dowel, then
drill with 4 mm.
Insert wing dowel F32 in wing and slide wing in place on
fuselage. Make sure wing and dowel fit perfectly and without
binding.
Correct, if necessary, then glue dowel in place.
Position wing on fuselage and align with centre line.
12 mm from the rear of the wing drill with 4 mm through centre
of wing and into R18/R19. Drill through R18/R19 with 5 mm and
from below epoxy in place retaining nut R31.
34
35
Fit canopy former R32 in place in fuselage. To achieve best
results, bevel off contact surfaces with upper sheeting,
triangular stock and canopy frame.
From behind glue magnet R33 and retainer R34 to former
(epoxy), then glue former R32 in place and secure with clamps.
Fit canopy former R35 in place in rear end of canopy. To achieve best results
bevel off contact surfaces with upper sheeting and triangular stock.
From behind glue magnet R33 and retainer R34 to former (epoxy), then glue
former R35 in place and secure with clamps.
Attention: Make sure you check polarity of magnets before you glue!
At front end of canopy glue in place former R36 and retaining tab R37 and
secure with clamps.
Note: Fuselage turned upside
down for clarity.
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F32
R31
R32
R35
R36
R37
R33
R33
R34
R34

38
39
Place tailplane R42 on building board (put cling film under-
neath), secure with pins and glue tips R43 in place. Chamfer
front edge of elevator R44 for sufficient controll throw.
From above glue in place control horn R45 in elevator and sand
front of control horn flush with front edge of elevator.
Glue together fin from parts R46, R47 and R48.
Finally, round off front edges of tail assembly with sanding block.
36
37
With drill and file make an opening in rear end of fuselage so that
clevis for elevator control can move freely and without binding
(ca. 6 mm wide, 7 mm high).
If necessary, correct opening when elevator control is installed.
Insert 0.8 mm piano wire R38 in snake R39.
Rough up snake at one end, epoxy or crimp clevis extender
R40 to snake and screw on clevis R41.
From the rear slide snake into snake outer. Make sure that
clevis moves freely and without binding between fuselage
sides.
R38
R40
R41
R42
R43
R43
R46
R47
R48
R44
R45
R39