Black Horse Model Travel Air Owner's manual

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

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TRAVEL AIR-Item code:BH06. Instruction Manual
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.
If you are inexperienced with basic R/C flight we strongly recommend you contact your R/C supplier
and join your local R/C Model Flying Club. R/C Model Flying Clubs offer a variety of training
procedures designed to help the new pilot on his way to successful R/C flight. They will also be 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.
Modelling knife.
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
Landing gear.....
To avoid scratching your new 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 air-
craft and to protect the table. Keep a couple of
jars or bowls handy to hold the small parts af-
ter you open the bag.
Please trial fit all the parts. Make sure you have
the correct parts and that they fit and are
aligned properly before gluing! This will 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 su-
perior 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: paint thinner, C/A glue accelerator, C/A glue
debonder and acetone. Do not let these chemi-
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-
installed rudder.
(1) Horizontal stabilizer with pre-
installed elevator halves.
SUGGESTION.
NOTE.

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TRAVEL AIR-Item code:BH06. Instruction Manual
+ 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.
+The glow plug clip must be securely attached
to the glow plug.
+ Do not flip the propeller with your fingers.
+ Keep loose clothing and wires away from
the propeller.
+ Do not start the engine if people are near.
Do not stand in line with the side of the propel-
ler.
+ Make engine adjustments from behind the
propeller only. Do not reach around the spin-
ning propeller.
Caution: this model is not a toy!
If you are a beginner to this type of powered
model, please ask an experienced model flyer
for help and support. If you attempt to operate
the model without knowing what you are doing
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
Even if you have already built a large number
of RC models please read right through 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.
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
be built in a very short time. 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
tasks competently - so please work slowly and
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.
Creases: Blow warm air over the area
and rub down with a soft
cloth.
SAFETY PRECAUTION.
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.
REPLACEMENT LARGE PARTS
3.Horizontal stabilizer
2.Wings panel(Left $ Right).
1. Fuselage.
5. Aluminium tube wing
4. Vertical stabilizer

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TRAVEL AIR-Item code:BH06. Instruction Manual
 1. Install the rubber grommets and brass
eyelets onto the aileron servo.
Top side.
Bottom side.
aileron.
REPLACEMENT SMALL PARTS
5. Plastic parts for elevator and rudder pushrod.
7. Spinner.
2. Fuel Tank.
6. Tail gear
3. Wheels.
4.Tie wrap
3.
3x12mm.
5x35mm.
1.
5.
2.
4.
6.
3x12mm.
7.
a
b
INSTALLING THEAILERON SERVOS.
1. Aluminium landing gear.

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TRAVEL AIR-Item code:BH06. Instruction Manual
2. Using a modeling knife, remove the cov-
ering servo tray.
Servo tray.
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.
Secure.
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.
Temporary pin to
keep hinge centered.
Assemble then apply drops of thin
C/A to center of hinge,on both sides.
Cut the covering
away from the slot.

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TRAVEL AIR-Item code:BH06. Instruction Manual
Repeat the procedure for the other wing
half.
2. Drill through 1.5mm (diameter) the ai-
leron using the control horn as a guide and
screw the control horn in place.
Bottom side.
Drill a
hole
1.5mm
5. Instal servo tray with aileron servo into
the wing as same as picture below.
Electric wire.
Servo tray.
Wing.
2x10mm.
1. Using a ruler & pen to draw a straight
line as below picture.
INSTALLINGTHEAILERON CONTROLHORN.
Install aileron control horn as same
as picture below.
Control horn of Aileron
Mark line.
2 x20mm.

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TRAVEL AIR-Item code:BH06. Instruction Manual
Secure
Control horn
of Aileron
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
and center the servo. Install the servo arm onto
the servo. The servo arm should be perpen-
dicular to the servo and point toward the mid-
dle of the wing.
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
out from the center of the arm to accommo-
date the aileron pushrod wire.
5. Using pliers, carefully make a 90 degree
bend down at the mark made. Cut off the ex-
cess wire, leaving about 4mm beyond the
bend.
6. Insert the 90 degree bend down through
the hole in the servo arm. Install one nylon
snap keeper over the wire to secure it to the
arm. Install the servo arm retaining screw and
remove the masking tape from the aileron.
Bend and
cut after.
M2 clevis.
Snap keeper.
Repeat the procedure for the other wing
half.
INSTALLING THE AILERON
LINKAGES.

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TRAVEL AIR-Item code:BH06. Instruction Manual
INSTALLING THE ENGINE MOUNT.
Locate the long piece of wire used for the
throttle pushrod. One end of the wire has been
pre-bend in to a “Z” bend at the factory . This
“Z” bend should be inserted into the throttle
arm of the engine when the engine is fitted onto
the engine mount. Fit the engine to the engine
mount using the screws provided.
INSTALLING THE ENGINE.
3x 20mm
Secure.
Mark point.
Drill a hole 2.5mm
diameter.

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TRAVEL AIR-Item code:BH06. Instruction Manual
INSTALLING THE STOPPER ASSEMBLY
1. The stopper has been pre-assembled at
the factory.
2. Using a modeling knife, cut one length of
silicon fuel line (the length of silicon fuel line is
calculated by how the weighted clunk should
rest about 8mm away from the rear of the tank
and move freely inside the tank). Connect one
end of the line to the weighted clunk and the
other end to the nylon pick up tube in the stop-
per.
3. Carefully bend the second nylon tube up
at a 45 degree angle (using a cigarette lighter).
This tube will be the vent tube to the muffler.
4. Carefully bend the third nylon tube down
at a 45 degree angle (using a cigarette lighter).
This tube will be vent tube to the fueling valve.
FUEL TANK.
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
a modeling knife. If flashing 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 ex-
pands 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.
Silicon not
included.

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TRAVEL AIR-Item code:BH06. 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 front of the tank should just about
touch the back of the firewall.
Blow through one of the lines to ensure
the fuel lines have not become kinked inside
the fuel t ank comp artment. Air should flow
through easily.
9. To secure the fuel tank in place, apply a
bead of silicon sealer to the forward area of
the tank, where it exits the fuselage behind the
engine mounting box and to the rear of the tank
at the forward bulkhead.
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.
Secure.
Fuel tank.
Tie wrap
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 SERVO.
Tie wrap.

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TRAVEL AIR-Item code:BH06. Instruction Manual
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 wire.
Throttle servo
Throttle servo
Secure.
Install the spinner backplate, propeller and
spinner cone. The spinner cone is held in
place using two 3mm x 12mm wood screws.
INSTALLING THE SPINNER.

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TRAVEL AIR-Item code:BH06. Instruction Manual
1. Install the rubber grommets and brass
collets into the elevator servo. Test fit the servo
into the servo tray.
2. Mount the servo to the tray using the
mounting screws provided with your radio sys-
tem.
elevator servo.
elevator servo.
Secure.
HORIZONTAL STABILIZER INSTALLATION.
See pictures below:
SERVO INSTALLATION.
ELEVATOR INSTALLATION.
1. Using a modeling knife, cut away the
covering from the fuselage for the stabilizer
and remove it.
Temporary pin to
keep hinge centered.
Assemble then apply drops of thin
C/A to center of hinge,on both sides.
Cut the covering
away from the slot.

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TRAVEL AIR-Item code:BH06. Instruction Manual
3. Mark the shape of the vertical on the left
and right sides onto the horizontal stabilizer
using a felt-tip pen
Remove
covering.
Mark pen
Bottom side
Center line.
2. Draw a center line onto the horizontal
stabilizer. Then slide the horizont al into the
fuselage.
4. Remove the stabilizer. Using the lines
you just drew as a guide, carefully remove the
covering from between them using a modeling
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 fail-
ure during flight
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
top and bottom of the stabilizer mounting area
and to the stabilizer mounting platform sides
in the fuselage. Slide the stabilizer in place and
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.
Epoxy glue
Remove
covering.

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TRAVEL AIR-Item code:BH06. Instruction Manual
Epoxy glue
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
rubbing alcohol.
Elevator control horn install as same as the
way of aileron control horn. Please see pic-
tures below.
Control horn of elevator.
C/A glue
Check to mark sure the wing and stabi-
lizer are paralell. If they are not, lightly sand
the opening in the fuselage for the stabilizer
until the stabilizer is paralell to the wing.
Top side
Bottom side.
2 x12mm.
ELEVATOR CONTROL HORN INSTALLA-
TION.

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TRAVEL AIR-Item code:BH06. Instruction Manual
Secure.
 Elevator pushrod install as same as the way
of aileron pushrod. Please see pictures be-
low.
ELEVATOR PUSHROD INSTALLATION.
Elevator
pushrod.
Cut.
Elevator servo.
Drill 1 hole with
1.5mm diameter.
Bend and
cut after.

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TRAVEL AIR-Item code:BH06. Instruction Manual
Elevator pushrod.
RUDDER SERVO INSTALLATION.
Rudder servo install as same as method of
elevator servo. See picture below:
Rudder servo.
Rudder servo.
Cut the covering
away from the slot.
VERTICAL INSTALLATION.
See picture below:
Control clasp.
Hinge.
Temporary pin to
keep hinge centered.
Assemble then apply drops of thin
C/A to center of hinge,on both sides.

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TRAVEL AIR-Item code:BH06. Instruction Manual
1) Using a modeling knife, remove the
covering from the top of the fuselage and the
covering from over the precut hinge slot cut
into the lower rear portion of the fuselage This
slot accepts the lower vertical.
Hinge slot.
Remove covering.
3. Mark the shape of the vertical on the left
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.
Mark pen.
2. Slide the rudder into the fuselage as
same as picture below.
Remove covering.

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TRAVEL AIR-Item code:BH06. Instruction Manual
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.
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
plac.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
stabilizer in place with T-pins or masking tape.
Allow the epoxy to fully cure before proceed-
ing.
Epoxy glue.
90º
Vertical
Stabilizer.
Horizontal
Stabilizer.
Remove covering.
Epoxy glue.
Top side
C/A glue
 1) Locate the two nylon control horns, two
nylon control horn backplates and four M2 x
12mm machine screws.
 2) Position the rudder horn on the bottom
side of rudder.
 3) Using a 1.5mm drill bit and the control
horns as a guide, drill the mounting holes
through the rudder halves.
RUDDER CONTROL HORN
AND PUSHROD INSTALLATION.
2 x 12mm.

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TRAVEL AIR-Item code:BH06. Instruction Manual
Secure.
Rudder
control horn.
Rudder pushrod.
Snap keeper
Drill a hole
1.5mm.
cut
Elevator pushrod.
Rudder pushrod.

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TRAVEL AIR-Item code:BH06. Instruction Manual


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-
der hinge line and the tail wheel bracket should
be centered on the plywood plate.
MOUNTING THE TAIL WHEEL
BRACKET.
3x12mm.


2. Using a pen, mark the locations of the
two mounting screws. Remove the tail wheel
bracket and drill 1mm pilot holes at the loca-
tions marked.


3. Secure the tail wheel bracket in place
using three 3mm x 12mm wood screws. Be
careful not to overtighten the screws.
Plastic parts of elevator and
rudder pushrod.
secure.