AirfoilZ Bearcat 32 Warbird Series User manual

Warbird Series
Bearcat - 32
Assembly Manual
Specifications
Wing Span: 32 inches
Wing Area: 210 in2
Fuselage Length: 26 inches
Weight (ready to fly): 11 to 13 oz.
Wing Loading: 7.5 to 8.9 oz/ft2
Designed by Jim Vigani
Version 1.0a - 8/27/07

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A Tech Hobbies,LLC Company
PO box 301
Edison, New Jersey 08817
Ph: [phone]
Fax: [phone]
Website: www.airfoilz.com
e-mail: [e-mail]
© Copyright 2007 all rights reserved
Limited Warranty
AirfoilZ takes pride in the care and attention given to the manufacture of the components in this
kit. The company warrants replacement of any materials found to be defective for their intended
use prior to their use in the construction of the model, provided the purchaser requests such
replacement within a one year period from the date of purchase, and the part is returned, if so
requested by the Company. No other warranty, expressed or implied, is made by the company
with respect to this kit. The purchaser assumes full responsibility for the risk and all liability for
personal or property damage or injury resulting from the purchaser’s use of the components of
this kit whether assembled or not.
The Company reserves the right to provide a full refund to the purchaser if the model does not
perform as advertised. Any refund is at the sole discretion of the Company.

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Introduction:
Thank you for choosing the Bearcat - 32 airplane. We have taken great care to provide a design
and kit components that, when properly assembled, will give you a high quality model with
outstanding performance. While the assembly is not complicated, the quality and ultimate
performance of your model will depend on the care you take while building. Please read these
instructions carefully and be sure that you understand them before you start. Take care to
assemble the components as shown and in proper alignment.
Warning
This radio-controlled model is not a toy and, if operated inappropriately can cause serious
bodily injury and property damage. It is the buyer’s responsibility to assemble the kit correctly
and properly install the motor, radio and all other equipment. The model must always be flown in
accordance with the safety standards of the Academy of Model Aeronautics (AMA).
This model is designed for high performance. While it is reasonably simple to assemble, it is not
intended for the novice flier. Do not attempt to learn to fly with this model! If you are an
inexperienced modeler, we recommend that you get the assistance of an experienced modeler to
help you with the assembly and initial flights. There are many local clubs that can offer help with
assembly and flight instruction. Information on local clubs can be found through the Academy of
Model Aeronautics. The AMA has over 2500 chartered clubs throughout the country. Information
on the AMA can be found at www.modelaircraft.org.
We do not recommend the use of hot glue for mounting components such as servos, control horns,
receivers or speed controls.
Recommended Power System:
This plane has been designed to use a 125 watt+ power system. Recommended motors include the
Hacker A20-26M, Hacker A 20-30M, and Scorpion 2212-22, a 15 amp speed controller, and a 1320
mAh, 3S Li-poly battery with an 8x6 to 8x8 propeller. We also have had great performance with an
APC 9x7.5 slow flyer prop cut down to 8-inch diameter. Other power systems with similar
capabilities can be used. Performance will vary depending on the specific power system selected.
For information on alternate power systems please visit http://3dxhobbies.com or your local hobby
shop.

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Kit Contents:
Before you start the assembly of this model, check to make sure that there are no missing parts and
that none of the parts have been damaged during shipment. If you have any questions with the
assembly or flying of this model, please contact us and we will be happy to assist you. If you need
replacement parts please provide the model name. The parts included in the kit are shown on the
Part Sheet included with the kit. The kit does not include the 0.04 inch wire for the pushrods, the
Dubro Mini E/Z Connectors, the Dubro E/Z Link.
Other items you may need that are not included with your kit:
Building Supplies:
In addition to the kit contents, we recommend having the following building supplies on hand to
complete the kit assembly in accordance with this manual.
 Foam safe (odorless) CA
 Foam safe CA “Kicker”
 Thin CA
 Gorilla glue
 5 and 15 minute epoxy
 Double back tape or spray adhesive
 Low tack masking tape (blue painter’s tape)
 Sanding block with 100 grit sandpaper
 Sanding stick or emery board (150 grit)
 Soldering iron and resin core solder
 1/32 inch and 1/16 inchdiameter drill bits
 Exacto knife with #11 blade
 Utility knife
 Small square
 36 inch ruler
 Needle nose pliers
 3/8 inch diameter brass tubing
 Diagonal cutting pliers
 0.04 inch diameter piano wire for pushrods
 3 Dubro Mini E/Z Connectors
 1 Dubro E/Z Link
Power and Control Equipment:
The following items are needed to provide power and control function to your model.
 Brushless outrunner motor with radial mount
 4 motor mounting screws
 Brushless motor speed control
 3 micro servos (Hitec HS55 or equivalent)
 3S Li-poly battery pack (TP 1320 Pro-Lite or equivalent)
 LI-poly battery charger
 3 channel micro receiver
 Y harness if 3 channel receiver selected
 3 to 6 channel transmitter

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Making a Sanding Block:
The leading edges of the elevator, the rudder, and both ailerons need to be beveled prior to
installing the hinges. This is best performed by the use of a 2-inch wide by 12 inch long, 100 or 120
grit sanding block or sanding bar. In addition, other areas of the airframe need to be sanded as
shown in this manual to complete the assembly and enhance appearance. If you do not have a
suitable sanding block, one can be easily made by securing a piece of 100 grit sand paper to a 2
inch x 12 inch x ¾ inch wooden block. The sandpaper can be secured to the block using either
double backed tape or spray adhesive. Make sure that the block is flat! A styrofoam block is
great for general sanding of the fuselage and non-beveled edges of the control surfaces.
Figure: 1
Figure: 2
Figure: 3
General Comments on Assembly:
While not difficult to assemble, the Bearcat kit is intended for persons with some building
experience. As such, the instructions are presented as a simple sequence that, when followed, will
help ensure that the airframe turns out straight and light. Improperly aligned surfaces and
unnecessary weight will only hinder its performance. Apply glue and epoxy in a thin uniform coat,
using only enough to achieve a strong bond. Excess glue or epoxy will only add unnecessary
weight and will not increase the strength of your model. Trial fit all components to ensure fit and

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alignment before applying any glue or epoxy. Keeping joints tight fitting will minimize the amount of
glue required and will ensure a strong bond. When gluing foam to foam, or foam to wood, use
only foam safe CA and foam safe kicker. There are two basic methods that can be used when
gluing flat pieces of foam together such as when gluing the foam doublers to the fuselage skin. The
first method involves applying CA to the smaller part, positioning it in place and then spraying a light
spray of foam safe kicker along the perimeter of the part. The second method involves applying CA
to the smaller part, and lightly spraying the mating part with foam safe kicker. The parts are then
joined.
Use a light touch while sanding. Foam cuts very quickly and excess pressure can limit your ability to
accurately shape the foam. Take extra care not to over sand. Avoid scratching the surface of the
Depron foam.
Graphics:
The Bearcat comes unpainted. We used Krylon H20 spray paint on the prototypes to paint the base
color. Insignias, vinyl numbers and striping are included with the kit.
Fuselage Assembly:
The fuselage assembly on the Bearcat consists of a plywood and foam crutch assembly covered
with a depron skin.
Fuse Assembly

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Skin Assembly
Skin Component Parts

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Crutch Assembly
Crutch Component Parts
Follow the steps in the order outlined below to ensure accurate alignment of the
components.

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Step 1
Glue the wing root doubler
in place with foam safe CA
being careful to ensure the
wing openings are in
alignment. Tip: Before
joining, apply CA to one
part and lightly spray
kicker on the other part.
Step 2
Using the plywood nose
doubler as a guide, glue
the top front doubler in
place with foam safe CA.
DO NOT GLUE THE
PLYWOOD NOSE
DOUBLER IN PLACE!
NOTE: The top front
doubler needs to be
positioned 3 mm from the
edge of the skin. An
alignment tab is provided
at the rear of the part to
ensure proper alignment.

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Step 3
Glue the lower rear doubler
and the foam stab support
in place with foam safe CA.
NOTE: The lower rear
doubler needs to be
positioned 3 mm from the
edge of the skin. An
alignment tab is provided
at the rear of the part to
ensure proper alignment.
Repeat Steps 1 to 3 for the other skin assembly making sure to make a
LEFT and a RIGHT side version!

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Step 4
Dry assemble all the
plywood crutch pieces
and check for fit. The
pieces should snap
together and self align.
If the fit is tight, lightly
sand the notches for a
snug fit. Note: the
motor mount and
motor mount support
are very similar in
appearance. The
motor mount is wider
than the motor mount
support. The motor
mount support is
shown in the picture.
Step 5
Glue the plywood
crutch parts together
with thin CA, then re-
glue with medium CA.
Insert foam formers
and glue in place with
medium foam safe CA.

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Step 6
Test fit the skins on
the crutch and check
that the slot in the
rear of the skin
mates with the
alignment tab on the
rear of the crutch.
Step 7
Glue the rudder and
turtle deck former in
place with medium
foam safe CA .

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Step 7a
Before gluing, make
sure the rudder is
positioned into the
rear slot on the lower
crutch member.

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Step 8
Glue the crutch to one
skin assembly from
the nose to just behind
the wing opening with
medium foam safe CA.
After the glue has set,
glue the skin to the
lower crutch member
from the wing opening
to the rear tab, making
sure the rear
alignment tab is
properly seated in the
slot. DO NOT GLUE
THE SKIN TO THE
RUDDER JUST YET!
Repeat Step 8 for the other skin.
Step 9
Glue the top edges of
the fuselage together
with medium foam safe
CA from just behind
the canopy to just in
front of the rudder
forming the turtle deck.

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Step 10
After the glue for the
top edges has set, glue
the skins to the rudder
with medium foam safe
CA.

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Step 11
Glue the front deck in
position with medium
foam safe CA.
Step 12
Glue the canopy top skin
and front top skin in
place with medium foam
safe CA. Tip: Before
gluing, lightly score the
backside of the top skin
with a ballpoint pen to
allow the foam to be bent
around the nose without
cracking. Pre-bend the
foam before gluing in
place.

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Step 13
Fit the hatch but do not
glue.

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Step 14
Cut the elevator servo
mount supports to size
and glue in place with
medium foam safe CA.
Space the supports to
match your servo.
The front servo mount is
positioned directly over
the crutch cross support.

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Step 15
Cap the servo mount
supports with the plastic
servo mounts.
Step 16
Glue the bottom skins in
position with medium
foam safe CA. Tip:
Lightly score the
backside of the bottom
skin with a ballpoint pen
to allow the foam to be
bent around the nose
without cracking. Pre-
bend the foam before
gluing in place.

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Step 17
Epoxy the motor mount
in position being careful
to make sure it is square
and flush to the motor
mount support. Cut
cooling air inlet holes in
nose. Tip: we find it
easier to pre-drill the
motor mounting holes
with a 1/32” drill before
gluing the motor mount
in place.