Black Horse Model Travel Air BH.06 Owner's manual

SPECIFICATION
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
Wingspan : 1,550 mm 61.02 in.
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
Length : 1,250 mm 49.2 in.
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Weight : 2.4 kg 5.28 Lbs.
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
Radio : 04 channels.


Servo : 05 servos.

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Engine : 40 - 46 2 stroke
52 4 stroke
Instruction Manual book
MadeinVietnam.

TRAVEL AIR. Instruction Manual
2
This instruction manual is designed to help you build a great flying aeroplane. Please read this
manual thoroughly before starting assembly of your TRAVEL AIR. Use the parts listing below to
identify 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
proceduresdesignedtohelpthenew pilotonhiswaytosuccessfulR/C flight.Theywillalsobeable
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
Landinggear.....
Toavoid scratching yournew airplane,do not
unwrap the pieces until they are needed for
assembly. Cover your workbench with an old
towel or brown paper, both to protect the
aircraftand toprotect thetable. Keepa couple
of jars or bowls handy to hold the small parts
after you open the bag.
Pleasetrialfitall theparts. Makesureyouhave
the correct parts and that they fit and are
alignedproperly beforegluing!Thiswill assure
proper assembly. TRAVEL AIR ARF is hand
made from natural materials, every plane is
unique and minor adjustments may have to
be 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
following: paint thinner, C/A glue accelerator,
C/A glue debonder and acetone. Do not let
these chemicals 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.

TRAVEL AIR. INSTRUCTION MANUAL
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+ This is not a toy
+ Be sure that no other flyers are using your
radio frequency.
+ Do not smoke near fuel
+ Store fuel in a cool, dry place, away from
children and pets.
+ Wear safety glasses.
+Theglowplug clipmust besecurelyattached
to the glow plug.
+ Do not flip the propeller with your fingers.
+ Keep loose clothing and wires away from
thepropeller.
+ Do not start the engine if people are near.
Do not stand in line with the side of the
propeller.
+ Make engine adjustments from behind the
propeller only. Do not reach around the
spinningpropeller.
SAFETY PRECAUTION.
 1. Install the rubber grommets and brass
eyelets onto the aileron servo.
3.Drill1,5mm pilotholes through theblock
of wood for each of the four mounting screws
providedwiththeservo.Installservointoaileron
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,
remove the masking tape and the servo lead
from the thread.
 2. Using a modeling knife, remove the
covering servo tray.
INSTALLING THEAILERON SERVOS.
Servo tray.

TRAVEL AIR. Instruction Manual
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5. Instal servo tray with aileron servo into
the wing as same as picture below.
Repeat the procedure for the other wing
half.
Electric wire.
Servo tray.
1. Using a ruler & pen to draw a straight
line as below picture.
INSTALLING THEAILERON CONTROLHORN.
3x40mm.
Nilon control clasp.
M3locknut.
Wing.
2x10mm.

TRAVEL AIR. INSTRUCTION MANUAL
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 2. Drillthrough6mm(diameter)the aileron
using the control horn as a guide and screw
the control horn in place.
3. Install aileron control horn as same as
picture below.
Bottom side.

TRAVEL AIR. Instruction Manual
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C/Aglue
C/Aglue
INSTALLING THE AILERON
LINKAGES.
1. Working with the aileron linkage for
now, thread one clevis onto one of the
threaded wires.
2. Attach the clevis to the outer hole in the
control horn. Install a silicone tube on the
clevis.
3. Plug the aileron servo into the receiver
andcentertheservo. Installtheservoarmonto
the servo. The servo arm should be
perpendicular to the servo and point toward
the middle of the wing.
Repeat the procedure for the other wing
half.
Control horn.
finishing.
4. Locate one nylon servo arm, and using
wire cutters,remove all but one of the arms.
Using a 2mm drill bit, enlarge the third hole
outfromthecenter ofthearmtoaccommodate
the aileron pushrod wire.
5.Usingpliers,carefullymake a90 degree
bend down at the mark made. Cut off the
excess wire, leaving about 4mm beyond the
bend.
6.Insertthe90degree bend down through
the hole in the servo arm. Install one nylon
snap keeper over the wire to secure it to the
arm. Installthe servoarm retainingscrew and
remove the masking tape from the aileron.
M2clevis.
Snapkeeper.
Repeat the procedure for the other wing
half.
Bend and cut after.

TRAVEL AIR. INSTRUCTION MANUAL
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JOINING THE WING HALVES.
1. Locate the aluminium wing dihedral
brace.
 2. Using a modeling knife, remove the
covering wing.
 3. Test fit the dihedral brace into each wing
half. The brace should slide in easily. If not,
use 220 grit sandpaper with a sanding block
and sand down the edges and ends of the
brace until it fits properly.
Top side.
Remove covering.
Maskingtape.
Apply masking tape.
Maskingtape.
Epoxyglue.

TRAVEL AIR. Instruction Manual
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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.
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.
INSTALLING THE STOPPER ASSEMBLY
1.Thestopper hasbeen pre-assembledat
the factory.
2.Using amodeling knife,cut onelength of
siliconfuelline (thelength ofsilicon fuellineis
calculated by how the weighted clunk should
restabout 8mmawayfromtherearofthetank
andmove freelyinside thetank). Connectone
end of the line to the weighted clunk and the
other end to the nylon pick up tube in the
stopper.
3.Carefullybendthesecondnylontubeup
ata 45degreeangle (usingacigarettelighter).
This tube will be the vent tube to the muffler.
4.Carefullybendthethirdnylontube down
ata 45degreeangle (usingacigarettelighter).
This tubewill bevent tubeto thefuelingvalve.
FUEL 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.
6. When satisfied with the alignment of the
stopper assembly tighten the 3mm x 20mm
machine screw until the rubber stopper
expands and seals the tank opening. Do not
over 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.
INSTALLING THE ENGINE MOUNT.

TRAVEL AIR. INSTRUCTION MANUAL
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Blow through one of the lines to ensure
the fuel lines have not become kinked inside
the fuel tank compartment. Air should flow
througheasily.
9. To secure the fuel tank in place, apply a
bead of silicon sealer to the forward area of
thetank, whereit exitsthefuselagebehind the
enginemountingboxandtotherearof thetank
at the forward bulkhead.
Do not secure the tank into place
permanently until after balancing the
airplane. You may need to remove the tank
to mount the battery in the fuel tank
compartment.
Locate the long piece of wire used for the
throttlepushrod. Oneendofthewire hasbeen
pre-bend in to a “Z” bend at the factory. This
“Z” bend should be inserted into the throttle
armofthe enginewhentheengine isfitted onto
theenginemount.Fittheengineto theengine
mount using the screws provided.
INSTALLING THE ENGINE.
Fueltank.

TRAVEL AIR. Instruction Manual
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INSTALLING THE SPINNER.
Installthe spinnerbackplate,propellerand
spinner cone. The spinner cone is held in
place using two 3mm x 12mm wood screws.
Pushrod wire

TRAVEL AIR. INSTRUCTION MANUAL
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1. Install the rubber grommets and brass
colletsintothe elevatorservo.Testfittheservo
into the servo tray.
2. Mount the servo to the tray using the
mounting screws provided with your radio
system. 3. Marktheshapeoftheverticalontheleft
and right sides onto the horizontal stabilizer
using a felt-tip pen
4. Remove the stabilizer. Using the lines
youjustdrew asa guide,carefully removethe
coveringfrom betweenthem usingamodeling
knife.
When cutting through the covering to
remove it, cut with only enough pressure
to only cut through the covering it’s self.
Cutting into the balsa structure may
weaken it. This could lead to possible
failure during flight
Center line.
Elevator servo.
ELEVATOR INSTALLATION.
SERVO INSTALLATION.
Remove covering.
HORIZONTAL STABILIZER
INSTALLATION.
1. Using amodeling knife, cut awaythe
covering from the fuselage for the stabilizer
and remove it.
2 . Draw a center line onto the horizontal
stabilizer. Then slide the horizontal into the
fuselage.

TRAVEL AIR. Instruction Manual
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6. After the epoxy has fully cured, re-
move
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.
inthefuselage.Slidethestabilizerin placeand
re-align. Double check all of your
measurements one more time before the
epoxycures. Removeanyexcess epoxyusing
a paper towel and rubbing alcohol and hold
the stabilizer in place with T-pins or masking
tape.
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
topandbottomofthestabilizermountingarea
and to the stabilizer mounting platform sides
Pen.
Remove
covering.
C/Aglue
Elevator control horn install as same as the
wayofaileroncontrolhorn.Pleaseseepictures
below.
3mm x 40mm.
M3 lock nut.
Nilon
control clasp.
Control horn of elevator.
ELEVATOR CONTROL HORN
INSTALLATION.

TRAVEL AIR. INSTRUCTION MANUAL
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ELEVATOR PUSHROD INSTALLATION.
Elevatorpushrodinstallassameastheway
ofaileron pushrod.Please seepictures below.
Drill 1 hole with 6 mm diameter.
C/Aglue

TRAVEL AIR. Instruction Manual
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Elevator
pushrod.
Cut.
Secure.
Secure.
Ben and cut.
Elevator servo. Elevator pushrod.

TRAVEL AIR. INSTRUCTION MANUAL
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3. Markthe shapeof theverticalontheleft
and right side on the rudder using a felt-tip
pen.
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.
VERTICAL INSTALLATION.
Control clasp.
Hinge.
2. Slide the rudder into the fuselage as
same as picture below.
Remove
covering.
Hingeslot.
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.
Pen.
Remove covering.
90º Vertical
Stabilizer.
Horizontal
Stabilizer.

TRAVEL AIR. Instruction Manual
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Controlhornof Rudder.
Drill 6mm diameter a hole of the mounting
rudder control horn on to the rudder .
Markpoint.
Pen.
3mm x 40mm.
M3 lock nut.
Nilon
control clasp.
and re-align. Double check all of your meas-
urementsoncemorebeforethe epoxycures.
Remove any excess epoxy using a paper
towel and rubbing alcohol and hold the stabi-
lizer in place with T-pins or masking tape.Al-
lowthe epoxyto fullycure beforeproceeding.
RUDDER CONTROL HORN
INSTALLATION.
Rudder control horn install as same as the
way of aileron control horn. Please see pic-
tures below.
Epoxyglue.
Epoxyglue.
C/Aglue
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

TRAVEL AIR. INSTRUCTION MANUAL
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C/Aglue
C/Aglue
Rudder
control horn.
RUDDER PUSHROD INSTALLATION.
Rudder pushrod install as same as the way
of aileron pushrod.
Rudder pushrod.
Bend and
cut after
Snapkeeper.
Elevator pushrod.
Rudder pushrod.
Rudder
pushrod.
Elevator
pushrod. Elevator
pushrod.

TRAVEL AIR. Instruction Manual
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ThrottleServo.
 1. Cut outtheswitchholeusing amodeling
knife. Use a 2mm drill bit and drill out the two
mounting holes through the fuselage side.

2. Secure the switch in place using the
two machine screws provided with the radio
system.
INSTALLING THE SWITCH.
INSTALLING THE THROTTLE PUSHROD.
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
servoconnector.Remove theexcessmaterial
from the arm.
After installing the adjustable metal
connector apply a small drop of thin C/A
to the bottom nut. This will prevent the
connector from loosening during flight.
Servo arm.
Connector.
Throttle servo.
Cut.
Throttle pushrod.

TRAVEL AIR. INSTRUCTION MANUAL
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Tie wrap.
Tie wrap.
Battery.
1)Assembleandmounting thewheel pants
as shown in the following pictures.
MAIN GEAR INSTALATION.
PARTSREQUIRED
Receiver.
INSTALLINGTHE RECEIVERANDBATTERY.

1. Plug the servo leads and the switch
leadinto the receiver. You may want to plug
anaileronextensioninto the receiver to make
plugging in the aileron servo lead easier
when you are installing the wing . Plug the
battery pack lead into the switch.

2. Wrap the receiver and battery pack in
the protective foam to protect them from
vibration. Use a rubber band or masking tape
to hold the foam in place.

3. Position the battery pack and receiver
behindthe fueltank.Use sing totwo tiewraps
to hold the battery and receiver securely in
place as picture below.
Donotpermanentlysecure thereceiver and
battery until after balancing the model.

4. Using a2mm drillbit, drilla holethrough
the side of the fuselage, near the receiver, for
the antenna to exit.

TRAVEL AIR. Instruction Manual
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2)Using thehardware provided,mount the
main landing gear to the fuselage.
Repeat the process for the other wheel.
 1. Set the tail wheel assembly in place
on the plywood plate. The pivot point of the
tail wheel wire should be even with the rud-
derhingelineand thetailwheel bracketshould
be centered on the plywood plate.
MOUNTING THE TAIL WHEEL
BRACKET.
Secure.
3x12mm.