Carl Goldberg Products Endurance 400 User manual

1
The EEnndduurraannccee440000is a electric
powered glider that can perform like a true sail plane. With its
aileron controls and at “V” tail, this glider will satisfy any pilots
dream of flying.
WARNING
A radio-controlled model is not a toy and is not intended for persons under 16 years old. Keep
this kit out of the reach of younger children, as it contains parts that could be dangerous. A radio-
controlled model is capable of causing serious bodily injury and property damage. It is the buyer's
responsibility to assemble this aircraft correctly and to properly install the motor, radio, and all other
equipment. Test and fly the finished model only in the presence and with the assistance of another
experienced R/C flyer. The model must always be operated and flown using great care and common
sense, as well as in accordance with the Safety Code of the Academy of Model Aeronautics (5151
Memorial Drive, Muncie, IN 47302, 1-800-435-9262). We suggest you join the AMA and become prop-
erly insured prior to flying this model. Also, consult with the AMA or your local hobby dealer to find an
experienced instructor in your area. Per the Federal Communications Commission, you are required
to use only those radio frequencies specified "for Model Aircraft."
LIMITED WARRANTY
Carl Goldberg Products, Ltd. has inspected and certified the components of this aircraft. The company urges the buyer to per-
form his own inspection, prior to assembly, and to immediately request a replacement of any parts he believes to be defective for
their intended use. The company warrants replacement of any such components, provided the buyer requests such replacement
within a period of 90 days from the date of purchase and provided the defective 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 buyer acknowledges and under-
stands that it is his responsibility to carefully assemble the finished flying model airplane and to fly it safely. The buyer hereby
assumes full responsibility for the risk and all liability for personal or property damage or injury arising out of the buyer's use of the
components of this kit.
CARL GOLDBERG PRODUCTS, LTD.
P.O. Box 818 Oakwood GA 30566 Phone #[phone] Fax # [phone] www.carlgoldbergproducts.com
©copyright 2004
EEnndduurraannccee
EEnndduurraannccee
440000
440000

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USING THIS INSTRUCTION MANUAL
Before you begin assembling your EEnndduurraannccee440000ARF,
take some time to read through this entire instruction book.
It is designed to take you step-by-step through the process
and to give you added information on motor and radio
selection and set-up, balancing your aircraft, and flying
your model. The time you spend will speed the assembly
process and help you avoid problems.
PREPARING FOR ASSEMBLY
You will need a work area of approximately 24 x 48" which has
been covered to protect it from adhesive, as well as cuts and
other damage. Many people cover their work area with a
sheet of dry wall (sheet rock) and/or waxed paper t o pre-
vent CA Glue and Epoxy from ruining the work surface.
CONSTRUCTION TIPS
IMPORTANT: ALWAYS READ A FEW STEPS AHEAD.
This will alert you to coming instructions and will help you
plan accordingly.
Using the Parts Identification section, familiarize yourself
with the various items included in your kit box.
Do not hesitate to ask questions. Your local hobby dealer
and area flyers will most likely be happy to help, as they
want you to have a successful flying experience.
You may also receive technical assistance from Carl
Goldberg Products, Ltd. via e-mail (questions@carlgoldberg-
products.com) or by telephone [phone].
ADHESIVES & GLUING TECHNIQUES
CA adhesives are specially formulated to firmly glue the
plywood, hardwood, and balsa used in your model and to
withstand the vibration and stresses of high performance
flight. However, there are times, such as when you are
installing the stabilizer and fin on the fuselage and want
more set-up time for careful alignment and positioning,
then you should use epoxy. Occasionally, you also will
want to use thin CA, which "wicks" into the surrounding
areas. Aliphatic resin glue or similar water-based glues can
also be used, but they will add to the assembly time
because they dry so much more slowly than CA glue.
Remember, when ever using any CA, you must be careful
to read instructions thoroughly, as you will have only sec-
onds for positioning of parts. Be sure to trial fit parts
together before gluing. Also, never use watery THIN type
CA glue for gluing plywood and hardwood parts. Thin CA's
do not adequately bond these areas.
CAUTION
Some people may experience an allergic reaction when
exposed to fumes from CA glue or epoxy. As with paints,
thinners, and solvents, it is always important to use glues
only where there is adequate ventilation to carry fumes
away. A fan is recommended. Also, special care must be
taken when using CA, as it will bond skin as well as other
surfaces. Before using any CA, carefully read all label pre-
cautions. When using CA, protective eye-wear and care in
keeping the glue away from the face is highly recommend-
ed. If CA does happen to get into the eye, hold lid open
and flush with water only. Seek immediate medical atten-
tion.
COVERING
The EEnndduurraannccee440000ARF is covered in a premium polyester
film chosen by many of the world's top flyers for its beauty,
toughness, and ease of application and repair. It is not
uncommon for ARF's to develop a few wrinkles in transit.
If this is true of your model, the situation is easily correct-
ed. Before you begin putting the pieces together, run
around the edge of the seams first then over the surface of
each section with an iron (either specially designed for air-
plane use or the more cumbersome household iron).
Apply the heat (set at about 350° F), following along with a
soft cloth and pressing down on the covering as you go
around. This will more firmly set the covering adhesive into
the wood and keep your aircraft covering tight and smooth
in the future. Once you have ironed the seams stay away
from them with the heat or the covering will slide when you
try to shrink the middle. If this happens the wrinkles will not
come out of the covering.
ITEMS NEEDED TO COMPLETE THIS AIRCRAFT
1 RADIO GUIDANCE SYSTEM (3 CHANNEL
MINIMUM REQUIRED WITH 3 SERVOS)
2 FUTABA 3108 SERVOS (AILERONS)
1 FUTABA 3101 SERVO (ELEVATOR)
1 MICRO RECEIVER (GWS)
2 6” AILERON SERVO EXTENSION WIRE
1 ELECTRONIC SPEED CONTROL (20 AMP
FOR LI-PO BATTERIES)
1 2 OR 3 CELL 1500 MAH LI-PO BATTERY
1 CA ACCELERATOR
1 1 OZ. BOTTLE CA MEDIUM GLUE
1 1/2 OZ. BOTTLE CA THIN GLUE
1 5 MINUET EPOXY
1 1/4” FOAM RUBBER
1 DOUBLE SIDED SERVO TAPE
1 ELECTRICAL TAPE
1 120 GRIT SAND PAPER
TOOLS AND SUPPLIES FOR ASSEMBLY
MODELING OR UTILITY KNIFE
WORK SURFACE (24" X48")
SMALL STANDARD & PHILLIPS SCREW-
DRIVERS
MASKING TAPE
NEEDLE NOSE PLIERS
24” RULER
FLEXIBLE STRAIGHT-EDGE
SOFT PENCIL
A FEW STRAIGHT OR "T" PINS
WIRE CUTTER (DYKES)
OPTIONAL HEAT GUN/COVERING IRON
HOT GLUE GUN

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Caution:
Before starting, carefully go over all high
stress areas with an epoxy or wood glue to
confirm all areas are well glued.
Warnings about Lithium Polymer batteries
NEVER charge Lithium Polymer batteries with a charger designed for
NiCd, NiMH, or any other type of battery chemistry. Use ONLY
the chargers listed under REQUIRES or equivalent substitutes.
Do not allow Li-Po cells to overheat at any time. Cells which reach
greater than 140° Fahrenheit (60C) will usually become damaged and
could catch fire.
Do not charge or discharge Li-Po cells on or near combustible
materials including paper, plastic, carpets, vinyl, leather, wood,
inside an R/C model or full size automobile.
Do not expose Li-Po cells to water or moisture at any time.
Do not store batteries near an open flame or heater.
Do not assemble Li-Po cells or pre-assembled packs together with
other Li-Po cells or packs.
Do not allow a Li-Po battery to be left unattended during charging or
discharging.
Always store Li-Po batteries in a secure location away from children
Always remove a Li-Po battery if model is involved in any kind of
crash. Carefully inspect the battery and connectors for even the
smallest damage. CAUTION, cells may be hot! Do not allow the
electrolyte to get into eyes or on skin. Wash affected areas
immediately if they come into contact with electrolyte

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Wing
Installing Ailerons
1. Collect the following parts:
(2) Wing ( Left & Right)
(2) Ailerons ( Left & Right)
(8) Mini CA hinges
(2) Wood control horns
3. Locate the pre-cut aileron hinge slots in both
sides of the wing. Using a hobby knife (#11
blade), slide the blade into each slot to make
sure it is cleanly cut.
Repeat this process with the ailerons, making
sure all hinge slots are clean.
4. Insert the CA hinges half way into the wing
and the ailerons. (Use a pin inserted into the
middle of the hinge to help keep the hinge in
the middle.)
Make sure that the aileron is against the wing
and evenly spaced at both ends of the wing
cut out.
Using thin CA glue, place one drop on all four
hinges top and bottom.
Repeat these steps for the other aileron.
1. Locate the pre-cut control horn slots in both
ailerons.
Using a hobby knife (#11 blade), slide the
blade into each slot to make sure the covering
is cleanly cut. The slot is 2-5/8” from the end
of the aileron
Making sure that the aileron is upside down,
insert the wood control horn in the slot.
2. Keep the control horn perpendicular to you
table top and the end flush with the top of the
aileron.
Thin CA glue the control horn into the aileron.
Repeat this process with the other aileron.
Aileron Servo Installation
1. Collect the following parts:
(2) Mini servos
(2) 6” servo extensions
(1) Electrical Tape
(1) Hex Nut
(1) 45cm length of string
(1) Double sided servo tape
(2) Nylon Clevises
(2) Threaded pushrods
(2) Nylon Swivel Keepers
1. Locate the servo hole in the bottom of the
wing
Using a hobby knife (#11 blade), remove the
covering over the hole.
2. Tie the hex nut to one end of the 45cm string.
Tape the other end of the string to the bottom
of the wing next to the servo hole.
Insert the hex nut into the servo hole and let it
fall down into the wing rib hole through the
wing till it exits the root wing rib hole.

5
3. Tape the hex nut to the bottom of the wing.
4. Plug one 6" extension wire into the servo.
Tape the servo wire to the extensions.
IMPORTANT! To ensure that any connections
located inside the wing will not come loose,
either when the wires are pulled, or during flying,
always tape them securely together with electri-
cal tape.
5. Un-tape the string that is next to the servo
hole.
Tie the end of the string to the end of the servo
extension.
Make sure that the string is pulling in the mid-
dle of the plug
Tape the string to the servo plug.
6. Insert the servo wire plug into the hole in the
rib in the aileron servo hole.
Slowly pull the servo extension through the
wing till it exits the center wing rib hole.
HINT: Look through the hole in the wing and
pull back and forth on the string and the
extension wire, too feed it through the wing.
You can also use a length of music wire
inserted through the wing with the extension
plug taped to it.
7. Insert the aileron servo in the hole in the wing.
Cut open the servo hole if required.
Caution: Do not cut the spars or past the ribs.
8. ChecK for servo arm clearance.
Also, check that you can get to the servo arm
screw for adjustment and removal.
We have include a 1/4” block of wood to be
placed under the aileron servo if required.
Futaba 3108 servo

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9. Using rubbing alcohol, clean the bottom of the
servo where the double sided tape will be
applied.
Making sure that the both the wing and the
servo are dust free, apply a piece of double
sided tape to the servo.
remove the other side of the tape and mount
the servo in the wing.
To help secure the servo more, glue the servo
in place using a hot glue gun.
10. Thread the nylon clevis onto the threaded
rod..
Attach the clevis to the wooden control horn.
Mark where the pushrod wire meets the servo
arm and make a 90 degree bend.
put the wire through the servo arm and attach
the nylon swivel keeper.
Cut off any excess wire.
“V” TAIL INSTALLATION
1. Collect the following parts:
(1) “V” Tail
(1) Fiberglass Fuselage
(1) 120 Grit Sand Paper
1. Using a soft lead pencil, mark the location
where the stab meets the fuselage.
2. Remove the stab from the fuse and, working
1/16" inside the drawn lines, carefully remove
the covering from the bottom of the stab. BE
CAREFUL TO AVOID CUTTING THE WOOD.
Sand the fuselage using 120grit sandpaper, at
the location where the “V” tail will be glued.
(Sand only enough to rough the surface for
the glue to stick).
Fuselage

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3. Spread epoxy on both the inside “V” of the
stab and the stab platform of the fuse.
Replace the stab on the “V” platform and,
check that the stab is resting completely flat.
Allow to dry.
Elevator & Pushrod
1. Collect the following parts:
(1) Pushrod Assembly
(2) elevators
(2) Wooden control Horns
(2) Nylon Clevises
(6) CA Hinges
2. Locate the pre-cut control horn slots in both
elevators.
Using a hobby knife (#11 blade), slide the
blade into each slot to make sure the covering
is cleanly cut. The slot is 3/8” from the end of
the elevators.
Making sure that the elevator is upright, insert
the wood control horn in the slot.
3. Keep the control horn perpendicular to you
table top and the end flush with the top of the
elevator.
Slide the elevator into the “V” tail using the
hinges
4. Repeat this process with the other elevator.
Align the two control horns so they are even
with each other. (See Photo)
Carefully pull the elevators back out of the “V”
tail and glue the control horns in place.
5. Re-insert the hinges into the elevators and
placet them back onto the “V” tail.
Make sure the tip of the elevator is even with
the tip of the “V” tail.
Using thin CA, glue the elevators in place.
Align the control horns
Even
6. thread the nylon clevises onto the end of the
elevator pushrod.
7. Insert the pushrod into the rear of the fuse-
lage.
Make sure the front of the pushrod rest under
where the servo arm will be.
7. Insert the elevator servo into the fuselage. (
We used a Futaba 3101 servo).
Making sure that the servo arm is straight to
the servo, mark the pushrod were the servo
arm hole meet.
Remove the pushrod from the fuselage.

8
8. Lay the pushrod on the table top just like it sits
inside the fuselage.
Bend the pushrod 90 degrees at the mark you
just made. Bend the wire so that you insert the
pushrod thru the servo arm. (See Photo
above)
Put the servo arm and the swivel keeper on
the pushrod. (See Photo above)
Insert the pushrod into the hole in the rear of
the fuselage.
9. Screw the servo arm onto the servo.
Mount the elevator servo like shown in the
photo above.
Speed control
The motor in the EEnndduurraannccee440000is a stan-
dard 400 brushed motor. The EEnndduurraannccee440000
uses a orbital drive with a 3.7:1 ratio. The
EEnndduurraannccee440000works the best using Li-Po bat-
tery packs. A 2 cell 1500 mAh Li-Po battery or
for the best performance a 3 cell 1500 mAh Li-
Po battery.
The speed controller needs to be
designed for Li-Po battery packs and able to
handle no less than 25 amps of current draw.
Connect your speed controller to the motor per
the instructions that comes with the speed con-
trol.
Battery & Receiver Location
Slide the battery behind the elevator
servo. Use foam to help hold the battery in
place or glue velcro on the battery and the tray.
Receiver
Plug in all the servos into the micro
receiver and place the receiver on top or in front
of the battery pack.
Stretch out the receiver antenna along
the top of the fuselage and tape in place.
You will also have to tape the wings to the
fuselage before flying.

9
CG Location and Control Throws
The EEnndduurraannccee440000balance point is 2-1/4 to 2-1/2” back from the
leading edge of the wing next to the fuselage. It is always better to
fly slightly nose heavy, then slowly move the balance point back till
the plane flies the way you like it.
Control Throws
Aileron 1/4” to 3/8”
Elevator 3/8” to 1/2”
With everything installed, mount the wing and care-
fully check the Center of Gravity (CG). One way is to
perch the model on the thumb and forefinger of your
left hand (if you’re right handed), while steadying the
model with the other. A much better way is to use a
balancing set-up, which can be made with a couple
of 1/4” dowels with rounded tops, spaced just
enough apart to clear the fuse. Mark the desired CG
on the underside of the wing, and then set the model
on the dowels at that location. Add weight if neces-
sary for balance. The least weight is needed when
added as far forward or back as possible.
DO NOT attempt to fly the model with the CG
EVEN SLIGHTLY BEHIND the rear most recom-
mended position.
Before going to the field to fly, with batteries fully-
charged, turn on receiver and transmitter and actu-
ate all controls many times until you are satisfied
with all functions. Prior to the beginning of each
day’s flying, make a range check of your equipment
in accordance with the manufacturer’s instructions in
general, with antenna collapsed, you should have at
least 100 feet range on the ground. To check this,
set the model facing away from you, turn on both the
transmitter and receiver switches, and walk away
while transmitting signals. Watch to see that no sig-
nals are missed until you are at least 100 feet away.
Do not attempt any flights unless the equipment
works perfectly.Be careful not to use your transmitter
when someone else on the field is flying or testing on
the same frequency.
LEARNING TO FLY
Flying R/C is both fun and challenging. As with other
portions of this book, the following section is meant to
introduce you to the basics. Read carefully before tak-
ing your model out to the field and attempting first flights.
And remember, becoming an R/C pilot takes time and
patience, but the rewards are well worth the effort.

10
FLYING THE ENDURANCE 400
CHECK YOUR EQUIPMENT
Prior to going to the flying field, with radio batteries fully
charged, turn on both receiver (Rx) and transmitter (Tx)
and actuate all controls many times until you are satis-
fied with all functions.
Before beginning each day's flying, make a range check
of your equipment in accordance with the manufacturer's
instructions. In general, with transmitter antenna col-
lapsed to 6"-8", you should have an at least 100 foot
range on the ground. To check this, turn on both the
transmitter and the receiver switches, set the model
heading away from you, and walk away while transmit-
ting signals to move the control surfaces. Watch to see
that no signals are missed until you are at least 100 feet
away. Only if the equipment works perfectly should any
flights be attempted. Again, be careful to not use your
transmitter when anyone else at the field is flying or
testing on the same frequency!
After the range check, stand behind the model and make
sure the control responses are correct. Moving the con-
trol stick to the right should give right rudder (on a 3-
channel set-up) . Moving the stick back or down on the
Tx should move the elevator up, and vice versa.
Finally, make sure that everything on your aircraft is
neatly and firmly in place-motor fastened down, servos
snugged down, receiver and battery wrapped in foam
rubber, etc. Prop and spinner must be tight. The receiv-
er antenna must be extended, not coiled up inside the
model. Nothing should be loose, or unfinished, or
unchecked.
With everything ready, the motor should be started for a
short time. While the motor is running, make sure the
control surfaces do not jitter or move until you command
them and that the motor switch also responds properly to
your command.
With transmitter and receiver switched on, hand launch
the model directly into the wind. Gently correct the flight
path as necessary. If any adjustments are needed to
maintain straight and level flight, get experienced help to
move the clevises.
In flight control. most of the beginner's trouble comes
from over-controlling or holding a signal too long. It is
better to operate your transmitter slowly and smoothly.
A troublesome tendency is letting the model get down-
wind. New flyers should try to keep the model upwind at
all times prior to the landing approach.
If you are a novice, seek the help of an experienced flyer.
Do not hesitate to ask one of the better flyers at the field
for help. Usually, they are glad to spend a little time to
get somebody started right, and they very likely were
helped in the same manner themselves.
WHERE TO FLY
Fly only in areas sanctioned for R/C and known to be
free of radio interference. Ask your hobby dealer or
other modelers if there is an R/C flying field that is used
by a local R/C club. This is the ideal place to fly. If you
don't know of an R/C club nearby, contact the Academy
of Model Aeronautics (AMA), at the address on the front
of this booklet, for information on a club in your area.
Remember: R/C flying fields need to have rules to help
prevent accidents, so ask about them before you turn
on any of your equipment! DO NOT TEST your trans-
mitter in the parking lot or anywhere nearby until
you are sure no one else is using your radio fre-
quency. This could cause another flyer to crash and
make you very unpopular!
If there is no club or other R/C flying site available,
locate a square area (preferably a grassy field), at least
four or five football fields long, which is free of power
lines, trees, poles, houses, busy streets and other
obstructions. It must be at least three miles away from
any areas where other R/C models, such as boats or
cars, are operated. It should also have a relatively
smooth surface, as it will take practice to learn precision
landings. If you find a suitable location, turn your receiv-
er on for 2 or 3 minutes to check that no one in the vicin-
ity is operating an R/C device which could affect your
receiver and cause your plane to crash.
The Endurance 400 was designed for long, slow, relaxed
flying - not loops or similar aerobatic maneuvers. Save
that kind of lying for your next, higher performance sport
plane. Practicing precise control and glide planning on
the Endurance 400 is good preparation for the demands
of advanced aerobatic flying.
We recommend you use 3 channels, as this will allow
you to cut power whenever you wish to do so. On your
first few flights, after a couple of minutes, you may feel
you have "had enough" and want to land and relax. A
2-channel system without motor control will not give you
this option; you will have to keep flying until the battery
power runs down.
You can expect a good solid 4 or 5 minutes of powered
flight with a properly charged battery. In this amount of
time, Endurance 400 will gain several hundred feet of
altitude and will allow you time to get oriented and famil-
iar with the control "feel." When the battery power
begins to run out, climb will slow down and the model
will begin a slow descent. You should continue flying
your same flying pattern as the model slowly glides.
For your initial landings, you should not be concerned
about trying to land at a specific spot. Your prime con-
cern should be a controlled landing, always into the
wind, with wing level. With practice, you will be able to
plan your approaches to land just about where you
want.