Black Horse Model Sputnik Owner's manual

Instruction Manual book
SPECIFICATION


 Wingspan : 1,320 mm. 51.97 in.


 Length : 1,240 mm. 48.82 in.


 Weight : 1.9kg. 4.18 lbs.


Parts listing required(not included)


 Engine: 25cu.in 02 stroke.


 Servo : 04-05 servos.


 Radio : 4 channels.


Electric Motor: EMAX 2826/06.


 Battery: 4 Cells-Li-Poly-14.8V- 3,200 mAh-20 c .
Speed Control: 60A MadeinVietnam.
ITEM CODE: BH 107

2
SPUTNIK - ITEM CODE:BH107. Instruction Manual
This instruction manual is designed to help you build a great flying aeroplane. Please read this
manualthoroughlybeforestartingassemblyofyour SPUTNIK.Usethepartslistingbelowtoidentify
all parts.
WARNING.
Please be aware that this aeroplane is not a toy and if assembled or used incorrectly it is
capable of causing injury to people or property. WHEN YOU FLY THIS AEROPLANE YOU
ASSUME ALL RISK & RESPONSIBILITY.
IfyouareinexperiencedwithbasicR/CflightwestronglyrecommendyoucontactyourR/Csupplier
and join your local R/C Model Flying Club. R/C Model Flying Clubs offer a variety of training
proceduresdesignedtohelp thenewpilotonhiswayto successfulR/Cflight.Theywillalsobe able
to advise on any insurance and safety regulations that may apply.
TOOLS & SUPPLIES NEEDED.
Thick cyanoacrylate glue.
30 minute epoxy.
5 minute epoxy.
Hand or electric drill.
Assorted drill bits.
Modellingknife.
Straight edge ruler.
2mm ball driver.
Phillips head screwdriver.
220 grit sandpaper.
90° square or builder’s triangle.
Wire cutters.
Masking tape & T-pins.
Thread-lock.
Paper towels.
Some more parts.
HARDWAREPACK
COWLING.
Landinggear.....
Toavoid scratching yournew airplane,donot
unwrap the pieces until they are needed for
assembly. Cover your workbench with an old
towel or brown paper, both to protect the air-
craftand toprotect thetable.Keepacoupleof
jars or bowls handy to hold the small parts af-
ter you open the bag.
Pleasetrialfitall theparts.Make sureyouhave
the correct parts and that they fit and are
alignedproperly beforegluing!Thiswillassure
properassembly. SPUTNIKARFis handmade
from natural materials, every plane is unique
andminor adjustmentsmayhave tobe made.
However, you should find the fit superior and
assembly simple.
The painted and plastic parts used in this kit
are fuel proof. However, they are not tolerant
of many harsh chemicals including the follow-
ing:paintthinner,C/Aglueaccelerator,C/Aglue
debonderandacetone. Donotletthesechemi-
cals come in contact with the colors on the
covering and the plastic parts.
PARTS LISTING.
FUSELAGE ASSEMBLY
(1) Fuselage.
WING ASSEMBLY
(1) Right wing half with pre-installed
aileron.
(1) Left wing half with pre-installed
aileron.
Tail section assembly
(1) Vertical stabilizer with pre-
installedrudder.
(1) Horizontal stabilizer with pre-
installedelevator halves.
SUGGESTION.
NOTE.

3
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Caution: this model is not a toy!
If you are a beginner to this type of powered
model,please askan experiencedmodelflyer
forhelp andsupport.Ifyouattempttooperate
themodel withoutknowingwhat youaredoing
you could easily injure yourself or somebody
else. Please keep your safety and well-being
in mind at all times.
Important: before you start construction
Evenifyou havealready built alarge number
ofRC modelspleaseread rightthrough these
instructions and check all the kit components
against the parts list. We have taken great
trouble to keep construction as simple as
possible, without making any compromises
in the area of safety.
Note regarding the film covering
Minor creases or bubbles may develop in the
film covering due to major fluctuations in
weather conditions (temperature, humidity
etc.); in rare cases you may even find a slight
warp in a component. These minor faults are
in the nature of film-covered built-up wooden
structures, and can easily be corrected using
a heat gun, as commonly used for modelling.
Creases: Blowwarm airoverthearea
and rub down with a soft
cloth.
Wing warp: Hold the panel twisted
gently in the opposite
direction to the warp, and
apply warm air to remove
the creases from the
covering.
SAFETY PRECAUTION.
Caution! do not heat the film more than is
absolutely necessary. If the air or the iron is
too hot, the film may melt and holes may be
formed.
This model is highly pre-fabricated and can
bebuilt inaveryshorttime. However,the work
which you have to carry out is important and
must be done carefully. The model will only
be strong and fly well if you complete your
taskscompetently -so pleaseworkslowlyand
accurately.
When self-tapping screws have to be
screwed into wood, apply a little white glue
to prevent them shaking loose: just squirt
white glue into the hole and fit the screw.
REPLACEMENT LARGE PARTS
+ This is not a toy
+ Be sure that no other flyers are using your
radio frequency.
+ Theglowplug clipmustbesecurely attached
to the glow plug.
+ Do not flip the propeller with your fingers.
+ Keep loose clothing and wires away from
thepropeller.
+ Do not start the motor if people are near.
Donot standinlinewiththesideof thepropel-
ler.
E. Vertical stabilizer
G. Decal sheet.
F.
B1.
C.
D. E.
A.
B2.
G.
A.Cowling.
B. Wing panel.
C. Fuselage.
D.Horizontal stabilizer.

4
SPUTNIK - ITEM CODE:BH107. Instruction Manual
 1. Install the rubber grommets and brass
eyelets onto the aileron servo.
INSTALLING THEAILERON SERVOS.
Bottom side
Aileron
C/Aglue
REPLACEMENT SMALL PARTS
2. Wheel pants.
1. Aluminium landing gear.
8.Plastic partsforelevator andrudderpushrod.
3.Spinner.
9. Tail gear set.
7. Wheels.
4. Fuel Tank.
6. Plastic - enginemount.
5.Aluminium tube
1. 2.
3.
4.
a. b.
a. b.
7. 9.
5.
8.
6.

5
SPUTNIK - ITEM CODE:BH107. Instruction Manual
2. Usingamodeling knife,remove the cov-
ering servo tray.
Removecovering
Bottom side
3. Drill 1,5mm pilot holes through the block
of wood for each of the four mounting screws
provided with the servo. Install servo into ai-
leron servo tray as same as picture below.
4. Using the thread as a guide and using
masking tape, tape the servo lead to the end
of the thread: carefully pull the thread out.
When you have pulled the servo lead out, re-
move the masking tape and the servo lead
from the thread.
Servo tray.
Secure
C/Aglue
C/Aglue
C/Aglue
C/Aglue
C/Aglue

6
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Secure.
Installing the aileron linkages as pictures
below.
INSTALLING THE AILERON
LINKAGES.
Aileronpushrod.
Aileronpushrod.
Repeat the procedure for the other wing
half.
5. Instal servo tray with aileron servo into
the wing as same as picture below.
Electric wire
Secure
Repeat the procedure for the other wing
half.INSTALLING THE AILERON
CONTROL HORN.
2mm X 12mm.
1)Insert aileroncontrol hornto theaileron.
2) Drill two 2mm holes through the aileron
using the control horn as a guide and screw
the control horn in place.
Drill a hole 2mm
diameter
Thread
Bottom side
2x10mm.
M2 M2 lock nut
70mm.

7
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Locate the aluminium wing dihedral
brace.
WINGATTACHMENT.
*** Test fit the aluminium tube dihedral brace
into each wing haft. The brace should slide in
easily. If not, use 220 grit sand around the
edges and ends of the brace until it fits prop-
erly.
Bottom side
THERE ARE TWO OPTIONS:
1. ELECTRIC MOTOR
2. ENGINE MOUNT.
1. OPTION 1: ELECTRIC MOTOR.
Drill a hole
4mm diameter.
INSTALLING THE ELECTRIC MOTOR
310 mm
12
Epoxyglue
Epoxyglue

8
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Tie wrap
Remove covering
Secure
Right side
Battery
50mm
230 mm
4 x 60 mm
50mm
Cut.

9
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Left side
2. OPTION 2: ENGINE MOUNT.
See pictures below:
INSTALLING THE ENGINE MOUNT.
Drill a hole
4mm diameter.
INSTALLING THE STOPPER ASSEMBLY
FUEL TANK.
1. The stopper has been pre-assembled at
the factory.
2.Using amodeling knife,cut onelength of
siliconfuelline (thelength ofsilicon fuellineis
calculated by how the weighted clunk should
restabout 8mmaway fromtherearofthetank
andmove freelyinside thetank). Connectone
end of the line to the weighted clunk and the
otherend tothenylonpickuptubein thestop-
per.
3. Carefullybend thesecond nylontube up
ata 45degreeangle (usingacigarettelighter).
This tube will be the vent tube to the muffler.
4 x 25mm

10
SPUTNIK - ITEM CODE:BH107. Instruction Manual
 8. Feed three lines through the fuel tank
compartment and through the pre-drilled hole
in the firewall. Pull the lines out from behind
the engine, while guiding the fuel tank into
place. Push the fuel tank as far forward as
possible,the frontofthetankshould justabout
touch the back of the firewall.
Blow through one of the lines to ensure
the fuel lines have not become kinked inside
the fuel tank compartment. Air should flow
througheasily.
Do not secure the tank into place perma-
nently until after balancing the airplane.
You may need to remove the tank to mount
the battery in the fuel tank compartment.
9. To secure the fuel tank in place, apply a
bead of silicon sealer to the forward area of
thetank, whereit exitsthefuselage behindthe
enginemountingbox andtotherearof thetank
at the forward bulkhead.
Secure
6. When satisfied with the alignment of the
stopper assembly tighten the 3mm x 20mm
machine screw until the rubber stopper ex-
pandsand sealsthetank opening.Do notover
tighten the assembly as this could cause the
tank to split.
7. Using a modeling knife, cut 3 lengths of
fuel line 150mm long. Connect 2 lines to the 2
vent tubes and 1 line to the fuel pickup tube in
the stopper.
Fueltank
4. Carefullybend thethird nylontube down
ata 45degreeangle (usingacigarettelighter).
This tubewill bevent tubeto thefuelingvalve.
When the stopper assembly is installed
in the tank, the top of the vent tube should
rest just below the top surface of the tank.
It should not touch the top of the tank.
 5. Test fit the stopper assembly into the
tank. It may be necessary to remove some of
the flashing around the tank opening using
amodeling knife. Ifflashing is present, make
sure none of it falls into the tank.
Vent tube
Fuelfilltube
Fuel pick- up tube
Silicon not included

11
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Markpoint
Markpoint
Drill a hole
2mm diameter.
INSTALLING THE ENGINE.
3 x 20mm
Secure.
Pushrod wire

12
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Secure
COWLING.
1. Slide the fiberglass cowl over the en-
gineand lineup thebackedgeofthe cowlwith
the marks you made on the fuselage.
2. While keeping the back edge of the
cowl flush with the marks, align the front of
thecowlwiththecrankshaftoftheengine. The
front of the cowl should be positioned so the
crankshaft is in nearly the middle of the cowl
opening. Hold the cowl firmly in place using
pieces of masking tape.
3. Slide the cowl back over the engine
andsecure itin placeusing fourwood screws.
See picture below.
4. Installthemufflerandmufflerextension
onto the engine and make the cutout in the
cowl for muffler clearance. Connect the fuel
and pressure lines to the carburetor, muffler
andfuel fillervalve.
Right side
Trim and cut after
Right side
3 x 12mm
Right side
Bottomside
Left side.

13
SPUTNIK - ITEM CODE:BH107. Instruction Manual
INSTALLING THE SPINNER.
Installthe spinnerbackplate,propellerand
spinner cone. The spinner cone is held in
place using two 3mm x 12mm wood screws.
3 x 12mm
Left side
Machine
screw.
Front view
Secure
After installing the adjustable metal con-
nector apply a small drop of thin C/A to
the bottom nut. This will prevent the con-
nector from loosening during flight.
Throttle servo
Secure
1. Install one adjustable metal connector
through the third hole out from the center of
one servo arm, enlarge the hole in the servo
arm using a 2mm drill bit to accommodate the
servo connector. Remove the excess mate-
rial from the arm.
INSTALLING THE THROTTLE PUSHROD.
Connector.
Servo arm.
Connector.
Throttle servo

14
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Secure
SERVO INSTALLATION.
ELEVATOR INSTALLATION.
2. Mount the servo to the tray using the
mountingscrews providedwithyourradiosys-
tem.
1. Install the rubber grommets and brass
colletsinto theelevatorservo.Testfittheservo
into the servo tray.
C/Aglue
C/Aglue
C/Aglue
Elevator servo
Elevator servo
HORIZONTAL STABILIZER.
See pictures below:
C/Aglue

15
SPUTNIK - ITEM CODE:BH107. Instruction Manual
C/Aglue
1. Draw a center line onto the horizontal
stabilizer. Then slide the horizontal into the
fuselage.
2 Using a modeling knife, cut away the
covering from the fuselage for the stabilizer
and remove it.
Center line
3. Marktheshape ofthe verticalon theleft
and right sides onto the horizontal stabilizer
using a felt-tip pen
Markline
4. Remove the stabilizer. Using the lines
youjustdrew asa guide,carefully removethe
coveringfrom betweenthem usingamodeling
knife.
When cutting through the cover-
ingto removeit, cut withonly enough pres-
sure to only cut through the covering it’s
self. Cutting into the balsa structure may
weaken it. This could lead to possible fail-
ure during flight
Remove
covering
Check to mark sure the wing and stabi-
lizer are paralell. If they are not, lightly sand
theopening inthefuselageforthe stabilizer
until the stabilizer is paralell to the wing.

16
SPUTNIK - ITEM CODE:BH107. Instruction Manual
5. When you are sure that everything is
aligned correctly, mix up a generous amount
of 30 minute epoxy. Apply a thin layer to the
topand bottomofthestabilizermountingarea
and to the stabilizer mounting platform sides
inthefuselage.Slidethestabilizerinplaceand
re-align. Double check all of your measure-
ments one more time before the epoxy cures.
Remove any excess epoxy using a paper
towel and rubbing alcohol and hold the stabi-
lizer in place with T-pins or masking tape.
Epoxyglue
Epoxyglue
6.Afterthe epoxy has fully cured, remove
the masking tape or T-pins used to hold the
stabilizer in place and carefully inspect the
glue joints. Use more epoxy to fill in any
gaps that were not filled previously and
clean up the excess using a paper towel and
rubbingalcohol.
C/Aglue
Elevator control horn install as same as the
way of aileron control horn. Please see pic-
tures below.
ELEVATOR CONTROL HORN INSTALLA-
TION.
Drill a hole 2mm
diameter.
Secure.
 Elevatorand rudderpushrod installassame
as the way of aileron pushrod.
M2 M2 lock nut.
2*12mm.
ELEVATOR PUSHROD INSTALLATION.

17
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Plastic parts of elevator
pushrod.
Rudder servo install as same as method of
elevator servo. See picture below:
C/Aglue
Cut.
Elevator
pushrod Elevator
pushrod
Bottom side
Rudder servo
Secure
Secure
Bottom side
Secure
VERTICAL INSTALLATION.

18
SPUTNIK - ITEM CODE:BH107. Instruction Manual
C/A glue
C/Aglue
C/Aglue
Hinge.
3. Markthe shapeofthe verticalon theleft
and right side on the rudder using a felt-tip
pen.
1) Using a modeling knife, remove the
covering from the top of the fuselage and the
covering from over the precut hinge slot cut
intothelower rearportion ofthe fuselageThis
slot accepts the lower vertical.
2. Slide the rudder into the fuselage as
same as picture below.
C/Aglue
Hingeslot
Markpoint
Rudder servo
Elevator servo
Throttle servo

19
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Epoxyglue
C/Aglue
Top side
C/Aglue
4. Now, remove the rudder and using a
modeling knife, carefully cut just inside the
marked lines and remove the film of the rud-
der. Just as you did with the horizontal stabi-
lizer, make sure you only press hard enough
to cut the film, not the balsa rudder.
5. Put the vertical stabilizer back in
place. Using a triangle, check to ensure
that the vertical stabilizer is aligned 90 de-
gree to the horizontal stabilizer.
90º
Vertical
Stabilizer.
Horizontal
Stabilizer.
6) When you are sure that everything is a
aligned correctly, mix up a generous amount
of 30 minute epoxy. Apply a thin layer to the
slot in the mounting platform and to the verti-
cal stabilizer mounting area. Apply epoxy to
the lower rudder hinge. Set the stabilizer in
place and re-align. Double check all of your
measurements once more before the epoxy
cures. Remove any excess epoxy using a
paper towel and rubbing alcohol and hold the
stabilizerin placewithT-pinsormasking tape.
Allow the epoxy to fully cure before proceed-
ing.
Remove
covering
Epoxyglue

20
SPUTNIK - ITEM CODE:BH107. Instruction Manual
Rudder control horn install as same as the
way of aileron control horn. Please see pic-
tures below.
RUDDER CONTROL HORN INSTALLA-
TION.
2x 20mm
Drill a hole
2mm diameter
Secure.
RUDDER PUSHROD INSTALLATION.
 Rudder pushrod install as same as the way
of aileron pushrod.
M2 M2 lock nut.
C/Aglue
Elevator
pushrod
Rudder
pushrod
Elevator
pushrod.
Bottom side
Elevator servo
Rudder servo
Throttle servo