AJ Aircraft 10th Anniversary 51" Slick 540 User manual

10th Anniversary 51” AJ Slick 540
Assembly Instructions

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Up Your Game! Fly AJ Aircraft
From all of us at AJ Aircraft, we thank you for your
business. Our custom designs, combined with top grade
materials, are assembled with precision and care to
provide you with one of the best airframes in the industry.
We have gone the extra mile to make the final assembly of
your airplane as simple and painless as possible.
Once your airplane is complete, we know it will provide you with countless hours of thrilling flight. Prepare
yourself for a new experience in R/C flight as you Up Your Game with AJ Aircraft!!
Building the airplane is very straight forward. The rudder cables are pre-installed, hinges are pre-installed but
not glued, and pre-installed blind nuts in the wing tips for the included SFG's make it easy to get this bird in
the air in no time flat.
The 51" AJ Slick is the perfect "throw in your car for a few flights at the field" airplane. After flying this baby
just once, we think it will be your go-to plane and put a smile on your face every time you fly it!
Safety Precautions and Warning
All of AJ Aircraft’s airframes have gone through many stages of extensive testing to ensure a high quality kit
which results in a safe and reliable airframe when assembled properly. Poor assembly practices along with
substandard equipment will lead to an unsafe model.
The safe operation of this model is your responsibility and yours alone. If you are a beginner or have never
flown a model of this caliber, you should solicit the help of an experienced pilot until you have become
comfortable with it. This product should not be considered a toy, but rather a sophisticated, working model
that functions much like a full scale airplane. Because of its performance capabilities, this product, if not
assembled and operated correctly, could cause injury to you or spectators and damage to property.
This aircraft should be flown in accordance to the AMA safety code. It is highly recommended that
you join the Academy of Model Aeronautics in order to be properly insured and to operate your model at
AMA sanctioned flying fields. If you are not willing to accept all liability for the use of this product please
return if to the place of purchase immediately.
AJ Aircraft does not accept responsibility or liability for damages resulting from use of this product.

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Contents
Contents..................................................................................................................................................................................2
Contents of Kit ........................................................................................................................................................................3
Recommended Items for Completion.....................................................................................................................................3
Tools Needed ..........................................................................................................................................................................3
Unboxing.................................................................................................................................................................................4
Optional Configurations..........................................................................................................................................................5
Covering ..................................................................................................................................................................................5
Wings ......................................................................................................................................................................................6
Landing Gear.........................................................................................................................................................................10
Fuselage ................................................................................................................................................................................12
Elevator.................................................................................................................................................................................14
Rudder...................................................................................................................................................................................16
Pull-Pull Rudder Control....................................................................................................................................................17
Push-Pull Rudder Control..................................................................................................................................................20
Motor ....................................................................................................................................................................................21
Cowl & Canopy......................................................................................................................................................................22
Finishing Notes......................................................................................................................................................................22
Radio Installation & Setup ....................................................................................................................................................24
Before starting, read through the entire set of instructions to familiarize yourself with the
process.
If there’s ever a question, contact AJ Aircraft.734-244-4015

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Contents of Kit
•AJ 51” Slick 540 fuselage reinforced with
exclusive Carbon-Kevlar technology.
•Pre-hinged main wings
•Side Force Generators (SFGs)
•Pre-hinged horizontal stabilizer
•Pre-hinged rudder
•Color matched, fastener free plastic canopy
•Color matched fiberglass cowl & wheel pants
•Carbon fiber wing tube
•Carbon fiber main gear
•Lightweight tailwheel
•Lightweight foam wheels and steel axles
•Matching set of side force generators
•Pre-drilled firewall with installed blind nuts
•Individual bags of high quality hardware
Recommended Items for Completion
•Motor –Power by AJ Aircraft:
o4S –AJ3910-24P/770KV
o5S –AJ3910-24P/660KV
o6S –AJ3910-24P/550KVAJ
•Batteries:
o4S 2800 mAH LiPo
o5s 2200 mAH LiPo
o6S 1800 mAH LiPo
oHook and loop battery strap.
•ESC - Castle Talon 60A
•Propeller –Falcon 14x7, 15x6 (Electric
ONLY)
•5 Channel Full Range
•Four high torque mini servos
(13mm X 35mm X 29mm)
•2” or 50mm Spinner
•Servo extensions:
•(2) x 6” for ailerons
•(1) x 18” for elevator
•(1) x 18” for rudder (push/pull only)
•Servo Arms:
o(2) x 1” for ailerons
o(1) x 1” for elevators
o(1) x 2.5” for pull/pull rudder
o(1) x 1” for push/pull rudder
•
Tools Needed
Blue Painter’s Masking Tape
Thin CA Glue
30 Minute Epoxy
Denatured Alcohol
Paper Towels
Removable Thread Locker (Loctite 242, Blue)
Metric & Imperial Allen Wrenches
Hobby Knife & Fresh Blades
Covering Iron (Trim Iron)
Clamps
Small Flat File
Electric Drill w/ Assorted Small Bits (1/16”, 5/64”)
Small Flat Blade Screwdrivers
Small Phillips Screwdriver
Sandpaper (150-220 Grit)
Needle Nose Pliers
Measuring Tape & Ruler

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Unboxing
Your airplane is packaged in a double box to help protect it during shipping. The best way top open the box is to cut the
tape on the end folds of the first box and slide the second box out. The lid on the second box simply lifts off.

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Optional Configurations
You have the option of using a pull-pull rudder servo or a push-pull rudder servo setup. Fasteners, control horns and
servo connecting rods are provided for optional rudder setups.
Covering
The covering on your Slick may have developed loose areas through temperature and humidity changes between
manufacturing and shipping. This may also occur during the summer heat. The covering may require retightening a few
times during your first summer of flying.
Take a few minutes to go over all of the seams making sure all edges are secure. Then proceed to shrinking any area
that may need tightening. (Use an iron on all seams. Use a heat gun on open areas and sheeted areas. An iron can be
used in open and sheeted areas but hold the iron slightly above the surface. You don’t want press the covering into the
wood. Using an iron sock will reduce scratches.
•Genuine Ultracote covering.
•White HANU870, True Red HANU866, Midnight Blue HANU885, Cub Yellow HANU884
At 200-220°F (93-104°C) the adhesive on UltraCote® becomes
active allowing the covering to be attached to the model. While
220° will fully bond the covering to the model it is well below
the temperature that causes UltraCote® to shrink.
At 300°F (149°C) the initial shrinking of UltraCote® begins.
At 350°F (176°C) UltraCote® reaches its maximum shrinking
point. Raising the temperature above this point will not cause
further shrinkage.
Use as little heat as needed. Using too much heat may cause
reshrinking issues later.
Pro Tip - If the iron you're using does not display the actual
temperature, here is a tip that will ensure your iron is properly
set.Water boils at 212°F. Allow your iron to warm up at a
medium setting. When the iron reaches its stabilized
temperature, carefully pour a few drops of water on the iron's
surface. Adjust the temperature until the water just begins to

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Wings
Carefully locate the aileron servo pocket. Shining a light
through opposite side of the wing will help highlight the
pocket location. Use a new hobby knife blade to cut
though the covering.
Gently pull off the servo wire installation string and
temporarily secure it out of the way. Do not pull it out of
the wing. (If there is glue left behind scrape it off so the
wood mounting surface is flat.)
Carefully locate the aileron control horn slots. Use a
covering iron to bond the covering in the area the control
horn will sit. Trim the covering away to expose the slots.
Be sure not to cut through to the top side covering.
The hinges should already be glued into the ailerons.
Give each of them a little pull to ensure they are securely
attached. It’s better to find a loose hinge now rather
than during a flight.
The wings are already slotted for the hinges. Use a
covering iron to secure the covering along the edge of the
wings. Look at the wing hinge slots closely. Make sure
the covering will not interfere when gluing the hinges.
Cut away any covering that covers the hinge slot.
Slip each of the aileron hinges into the wing. Align the
end of the aileron to the wing tip.
Apply a piece of tape next to each hinge. This will help
you locate the hinges when you begin gluing them.
Check the aileron position at the hinges and wing tip
again before gluing.

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Push the aileron tight against the wing closing the gap
between the two of them. Move the aileron to its
maximum desired deflection. Notice how the hinges pull
out slightly. If you close the hinge gap tightly you may
have trouble reaching maximum deflection of the aileron.
Experiment with the hinge position finding the best fit
before gluing.
Start with the hinge near the wing tip. Flex the aileron
slightly and apply a few drops of thin CA glue to one side.
Flex the aileron to its maximum position and return to
center. Then glue the opposite side.
Close the gap between the aileron and wing to the
desired position at the fuselage end of the wing half. Flex
the aileron slightly and apply a few drops of thin CA glue
to both sides of the hinge. Again move the aileron back
and forth to its maximum positions. Once the end hinges
are securely positioned you can apply a few drops of thin
CA to both sides of the remaining hinges.
Use sand paper to roughen the lower portion of the
control horns on both sides. This will help the epoxy
bond to the control horn parts.
Test fit the control horn in the slot. Trim or file the slot as
needed to achieve a snug fit. (Be careful you don’t poke
through the other side of the aileron.)
The control horn should go all the way in until the
shoulder contacts the aileron. The linkage hole in the
control horn should be aligned with the hinge centerline.
With the control horn in position apply masking tape
around it. This will keep excess epoxy off the covering.

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Apply epoxy to the slot in the aileron. Use a pin to help
push the epoxy in.
Apply epoxy to the control horn and insert it into the slot.
Wipe away excess epoxy using a paper towel and
denatured alcohol.
Check the alignment along the hinge line as you did when
you test fit the control horn. Reposition as needed.
Allow the epoxy to partially cure. Peel away the masking
tape after the epoxy is securely holding the control horn
in place and still soft enough to easily remove the tape.
Set the wing aside and let the epoxy fully cure.
Connect the servo to a receiver and power supply. Turn
on your transmitter. Set trim and sub trim to zero. Install
a servo arm on the servo about perpendicular to the
servo’s side. Use the transmitter’s sub trim to make it
exactly perpendicular to the side of the servo.
You may use a standard size servo or a mico size with an
adapter plate shown below.
Fit the adapter plate into the servo pocket if you are
using the micro size servo. You may need to sand the
edges slightly to fit it in. The front corner of the servo
pocket should be tilted away from the aileron control
horn as shown.

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Attach the servo wire to the installation string and gently
pull the wire through the wing as you insert the servo
into the wing.
Insert the servo into the pocket with the drive spline
towards the front of the wing. Pre-drill for the servo
mounting screws using a 1/16” drill. Remove the servo
and apply a drop of thin CA glue into each mounting
screw hole. This will harden the wood around the screws
and provide a more secure installation. Allow the CA glue
to dry before reinstalling the servo.
Assemble a ball link to each end of a connecting rod.
Use a socket head screw, a flat washer and a nylon lock
nut to connect a ball link to the servo control horn. (The
brass ball in the link is offset. The larger reveal side
should be against the control horn and servo arm shown
below.)
Check the length of the assembly to the servo arm with
the aileron level with the wing. When the correct length
of the assembly is found, connect the ball link to the
servo arm. (Always adjust the connecting rod length with
the servo powered up and centered.)
Carefully locate the mounting holes in the side force
generators and trim away the covering. The wing tips
have a blind nut installed beneath the covering. Use a
hobby knife to trim away the covering. (Use the holes in
a spacer plate to help locate the holes in the wing tip.)
Assemble the spacer plate and the side force generator to
the wing with the supplied 3mm screws and washers.

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Landing Gear
Landing gear parts bag contents are shown below.
The landing gear screws (3mm) are supplied installed in
the fuselage. Remove these screws.
Install the carbon fiber landing gear using 2 washers from
the parts bag and the socket head screws. Apply a drop
of thread locker as you install these screws.
The filler block can be held in position with strips of
covering material, packing tape, or it can be held in
position with hook and loop material as described below.
(If you use packing tape you may need to trim the width of the
tape. Roll the tape out with the sticky side up. Lay a straight
edge down on the tape and cut with a new blade.)
To attach the filler block with hook and loop adhesive
tape attach two ¾” pieces on the landing gear next to the
screws.
Then cut or sand recesses into the filler block to
accommodate the thickness of the hook and loop tape.
Start with shallow cuts and test fit it to the landing gear.
If the filler block does not sit flush with the bottom of the
airplane cut and sand a little more. Continue until you
get a nice fit and the hook and loop tape has a firm grasp.
It may also be necessary to cut some clearance around
the holes for the screws and washers.

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File a flat on the wheel axels perpendicular to the axel
wrench flats.
Install a wheel on the axel with a wheel collar. Position
the collar set screw over the flat you filed.
Insert the wheel and axel into the wheel pant, then into
landing gear. Align the wheel pant indentation with the
landing gear. Add a nylon lock nut and tighten.
Install the tailwheel using 2 of the 3 wood screws.
Position the joint of the tail wheel assembly directly over
the rudder hinge line and mark the position of the
screws. Turn the screws into the fuselage and rudder.
Remove the screws, add a drop of thin CA glue to each
hole to strengthen the wood, and reinstall the screws.
The third screw is used to secure the tiller arm to the
rudder after it’s installed. Do not fully tighten the tiller
arm screw. The slot in the tiller arm allows the rudder to
move freely.

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Fuselage
Inspect the fuselage for any interior joints that may have
loosened as a result of shipping & handling. Apply thin
CA glue around the joints of the fuselage core, firewall,
fuselage formers, and rudder servo tray to strengthen.
Locate the mounting holes for the wing. Use an iron to
seal the covering around the edges of the pocket before
trimming. There will be 2 holes for wing alignment pins,
1 hole for the wing bolt, 1 slot for the servo lead, and 1
large hole for the wing tube. Measuring from the front
edge of the firewall the holes can be found at 3”, 5 7/8”,
7 ¼”, 12 ¾”. You can also locate the holes by pocking a
pin through the covering from the inside out.
Cut open the pocket just after the second small hole.
This is where the aileron servo wire will enter the
fuselage.
Locate the horizontal stabilizer pocket. Use an iron to
seal the covering around the edges of the pocket before
trimming. Use a new hobby knife blade to cut though the
covering.

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The elevator servo pocket is on the left side of the
airplane about 4 ½” from the end of the fusuelage. Use
an iron to seal the covering around the edges of the
pocket before trimming.
The servo pocket on the right side of the fuselage is used
for the rudder servo if you decide to use a push-pull
configuration. Do not cut this pocket open if you plan to
use the pull-pull cable for the rudder.
Slid the horizontal stabilizer through the fuselage pushing
it all the way forward. Center it side to side using a ruler
or tape measure.
Install and center the main wing tube. Look at the plane
from the back forward to make sure that the horizontal
stabilizer is parallel with the wing tube. Notice that the
horizontal stabilizer is tapered which may obscure the
actual alignment. If the stabilizer is not aligned use shims
or sand inside the pocket until it’s parallel.
Position the stabilizer perpendicular to the fuselage and
parallel to the main wing tube. Measure the distance
between the canopy latch and the corners of the
horizontal stabilizer. Adjust the stabilizer until the
measurements on both sides are equal. Continue
checking the stabilizer to ensure it is still centered side to
side as described above. Extra time spent here will go a
long way to improve the flight characteristics of your
airplane.
Once the horizontal stabilizer is positioned glue it in place
with thin CA glue. Wick glue in on left and right sides, top
and bottom. The use of an applicator tip is suggested to
control the flow of thin CA glue and get it exactly where
you want it.

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Elevator
The elevator hinges should already be glued in. Give each
of them a little pull to ensure they are securely attached.
The jointer plate between the elevator halves is also
already glued into one half of the elevator.
Install a control horn in the elevator using the same
procedure used when assembling the ailerons. Make
sure you are working with the left elevator half.
•Use a covering iron to bond the covering in the area
the control horn will sit.
•Trim the covering away to expose the slot.
•Sand the lower portion of the control horn.
•Test fit the control horn. The shoulder contacts the
elevator and the linkage hole should be aligned with
the hinge centerline.
•Mask around slot.
•Glue with 30 minute epoxy.
•Check the alighment again.
•Let cure.
•Remove masing tape.
Use sandpaper to roughen up the jointer plate where it
engages the right elevator half. This will allow the epoxy
will adhere better.
The horizontal stabilizer is already slotted for the hinges.
Use a covering iron to secure the covering along the edge
of the stabilizer. Look at the stabilizer hinge slots closely.
Make sure the covering will not interfere when gluing the
hinges. Cut away any covering that covers the hinge
slots.
Test fit the elevator joiner plate to the opposite elevator
half. Ensure the elevator halves are not twisted. Hold
one half of the elevator in position and check the
alignment of the other side. Check the gaps at the ends
of the stabilizer. Adjust the slot in the elevator or file the
edges of the jointer plate as needed to achieve a good fit.
Apply masking tape around the jointer slot in the right
elevator half.

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Apply masking tape to the horizontal stabilizer to prevent
epoxy from getting where you don’t want it.
Put the right elevator half in position on the horizontal
stabilizer.
Do not glue hinges yet.
Prepare 30 minute epoxy and apply it to the slot in the
elevator and the jointer plate.
Install the right elevator and position it as you did during
the test fit.
Use a paper towel and alcohol to wipe away excess epoxy
that is pushed out. Remember to check the bottom side.
Remove all masking tape right away and clean again.
Position the elevator as your did during the test fit.
Check it at the ends of the stabilizer.
Tape the elevator tightly in position algined to the
stabilizer at each counter balance. Tape across the hinge
line to keep the elevator assembly straight.
After the epoxy has had plenty of time to cure remove all
the masking tape.
Center the elevator by looking at the ends of the
stabilizer. Push the elevator tight against the stabilizer
closing the hinge gap. Experiment with the hinge position
finding the best fit with a minimum gap and best travel
before gluing.
Flex the elevator slightly and apply a few drops of thin CA
glue to each hinge. Flex the aileron to its maximum
position and back to center. Then glue the opposite side.

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Connect the servo to a receiver and power supply. Turn
on your transmitter. Set trim and sub trim to zero. Install
a servo arm on the servo about perpendicular to the
servo’s side. Use the transmitter’s sub trim to make it
exactly perpendicular to the side of the servo.
Attach an 18” servo extension onto the elevator servo
lead and use a safety clip to secure the connection.
Insert a servo into the elevator servo pocket with the
drive spline towards the front of the fuselage. Pre-drill
for the servo mounting screws using a 1/16” drill.
Remove the servo and apply a drop of thin CA glue into
each mounting screw hole. This will harden the wood
around the screws and provide a more secure
installation. Allow the CA glue to dry before reinstalling
the servo.
Assemble a ball link to each end of a connecting rod. Use
a socket head screw, a flat washer and a nylon lock nut to
connect a ball link to the servo control horn.
Adjust the length of the connecting rod to the servo arm
with the elevator aligned with the stabilizer. When the
correct length of the assembly is found, connect the ball
link to the elevator control arm on the inside as shown.
(Always adjust the connecting rod length with the servo
powered up and centered.)
Rudder
The rudder control can be configured as a push-pull or as
a pull-pull cable system.
The pull-pull control horn is located approximately 2 7/8”
from the bottom of the rudder.
The push-pull control horn is located approximately 9/16”
from the bottom of the rudder.

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Pull-Pull Rudder Control
Carefully locate the control horn slot and cut away the
covering on both sides of the rudder.
Use sand paper to roughen up the center of the control
horn so the epoxy will adhere better. File a radius on the
corners so the control horn can be rotated through the
rudder slot.
Tests fit the control horn to the slot. Use a file to modify
the slot as needed. Center it side to side and align the
holes with the hinge line. The control horn should be
symmetrical about the hinge line.
Apply masking tape around the control horn slot on both
sides of the rudder.
Use 30 minute epoxy to glue the control horns in place.
Center the control horn, peal the masking tape away, and
clean up with alcohol.
Check the control horn alignment, centering it side to
side and align the holes with the hinge line. The control
horn should be symmetrical about the hinge line.
Position the rudder and control horn so gravity does not
reposition the control horn as the epoxy cures.

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The hinges should already be glued into the rudder. Give
each of them a little pull to ensure they are securely
attached. The vertical stabilizer is already slotted for the
hinges. Use a covering iron to secure the covering along
the edge of the vertical stabilizer. Look at the hinge slots
closely to make sure the covering will not interfere when
gluing the hinges. Cut away any covering that covers the
hinge slot.
Slip each rudder hinges into a slot. Check the gap at the
top of the vertical stabilizer and the rudder counter
balance. Push the rudder tight against the stabilizer
closing the gap between the two of them. Move the
rudder to its maximum desired deflection. Experiment
with the hinge position finding the best fit before gluing.
Start with the top hinge. Flex the rudder slightly and
apply a few drops of thin CA glue to one side. Flex the
rudder to its maximum desired position. Then glue the
opposite side and other hinges.
Connect the servo to a receiver and power supply. Turn
on your transmitter. Set trim and sub trim to zero. Install
a servo arm on the servo about perpendicular to the
servo’s side. Use the transmitter’s sub trim to make it
exactly perpendicular to the side of the servo.
Take 2 ball links out of the “Extra” parts bag. Tread the
brass cable eyes about half way into the ball links.
Connect the ball links to the rudder servo arm using a pair
of holes that match the rudder control horn holes as
close as possible.
Assemble the ball links to the control arm using the 2mm
screws and lock nuts.

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Install the rudder servo into the fuselage and pre-drill for
servo mounting screws using a 1/16” drill. Install the
servo with the spline shaft towards the front of the
airplane using the wood screws that came with your
servos. Remove the screws and servo. Apply a drop of
thin CA glue into each mounting screw hole. This will
harden the wood around the screws and provide a more
secure installation. (Allow the CA glue to dry before
reinstalling the servo.)
Start the cable assembly at the servo end inside the
fuselage. Straighten out the cables and determine which
cable is on the left and which cable is on the right. The
cables should cross inside the fuselage once. The cable
on the left at the rudder should be connected to the
servo control horn on the right.
Thread on 2 crush sleeves and the brass cable eye.
Loop around the cable eye and go back through a crush
sleeve.
Loop around the crush sleeve and back through the
sleeve again. Slide the second sleeve over the tail.
Adjust the loops and crimp the sleeves with the non-
serrated surface of standard plyers.
Assemble 2 ball links and cable eyes to the rudder control
horn using 2mm screws, a washer, and lock nut.