Carl Goldberg Products ULTIMATE User manual

INSTRUCTIONS
Welcome to the world of Ultimate flying! Now that you're an experienced R/C pilot, you're ready to step up to
a higher level of aerobatic flying. And we've made sure this ARF version won't disappoint. With just the same
flight characteristics as the kitted version, you'll soon know why the Carl Goldberg Products Ultimate has
been America's favorite sport biplane since 1990.
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
(www.modelaircraft.org). We suggest you join the AMA and become properly 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 fre-
quencies 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.
1
PT. #2045 6/03
The
Ultimate ARF
CARL GOLDBERG PRODUCTS, LTD.
P.O. Box 818 Oakwood GA 30566 Phone #[phone] Fax # [phone] www.carlgoldbergproducts.com
© Copyright 2000 Carl Goldberg Products LTD.

ITEMS NEEDED TO COMPLETE THIS AIRCRAFT
1 RADIO GUIDANCE SYSTEM (4 CHANNEL
MINIMUM REQUIRED)
2 12” AILERON SERVO EXTENSION WIRES
1 Y-HARNESS
1 ENGINE .60-.90 2-CYCLE, .90-1.20 4-
CYCLE AND MUFFLER
1 2 OZ. BOTTLE CA GLUE
1 1/2 OZ. BOTTLE CA GLUE
1 EPOXY
1 8 x 12 FOAM RUBBER
OPTIONAL:
1 PILOT FIGURE
1 SWITCH HARNESS
*
NOTE: The Ultimate ARF covering matiches
Bright Yellow(#872), Deep Blue(#873)
UltraCote®.
UltraCote® is a registered trademark of Horizon Hobby Distributors
TOOLS AND SUPPLIES FOR ASSEMBLY.
MODELING OR UTILITY KNIFE
WORK SURFACE (24" X70")
ELECTRIC DRILL
1/16”, 3/32”,1/8", 3/16”, 5/32”, 1/4”, 5/64”
7/32” DRILL BITS
SMALL STANDARD & PHILLIPS SCREW-
DRIVERS
MASKING TAPE
NEEDLE NOSE PLIERS
MOTO TOOL
24” RULER
FLEXIBLE STRAIGHT-EDGE
30-60-90° x 6" TRIANGLE
SOFT PENCIL
A FEW STRAIGHT OR "T" PINS
ADJUSTABLE WRENCH
WIRE CUTTER (DYKES)
OPTIONAL HEAT GUN/COVERING IRON
ACID BRUSH
ELECTRICAL TAPE
SOLDERING IRON, FLUX, SOLDER
PIECE OF MEDIUM SANDPAPER
5 FT. LENGTH OF STRING
2

INTRODUCTION
USING THIS INSTRUCTION MANUAL
Before you begin assembling your ULTIMATE ARF, 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 engine and radio
selection and set-up, balancing your aircraft, and flying
your model. The time you spend will speed the assem-
bly process and help you avoid problems.
PREPARING FOR ASSEMBLY
You will need a work area of approximately 24 x 70" 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
prevent CAglue 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.
As you work, CHECK OFF EACH STEP in the box pro-
vided, so that you are sure you do not forget anything.
Do not hesitate to ask questions. Your local hobby deal-
er and area flyers will most likely by happy to help, as
they want you to have a successful flying experience.
You may also receive technical assistance from Carl
Goldberg Models via e-mail (questions@carlgoldberg-
products.com) or by telephone [phone].
tCAUTION
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 recom-
mended. If CA does happen to get into the eye, hold lid
open and flush with water only. Seek immediate medical
attention.
COVERING
The Ultimate ARF is covered in genuine a premium poly-
ester 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 easi-
ly corrected. Before you begin putting the pieces togeth-
er, run over the surface of each section with an iron
(either specially designed for airplane use or the more
cumbersome household iron) or use a modeling heat
gun. Apply the heat (set at about 350° F), following
along with a soft cloth and pressing down on the cover-
ing as you go around. This will more firmly set the cov-
ering adhesive into the wood and keep your aircraft cov-
ering tight and smooth in the future.
3

1. Collect the following parts:
(1) Top Wing
(1) Bottom Wing
(4) Ailerons
(16) Jet Hinges
WING CONSTRUCTION
Aileron Installation
2. Locate the pre-cut aileron hinge slots in both
the top and the bottom wings. Using a hobby
knife (#11 blade), slide the blade into each of
the slots to make sure they are cleanly cut.
Repeat this process with the ailerons, mak-
ing sure all hinge slots are clean.
3. Place a straight pin into the center of each of
four Jet Hinges.
3. Slide four hinges into the hinge slots on one
side of a wing The straight pin will prevent
the hinges from going further than halfway
into the wing.
4. Select one of the ailerons and insert the
exposed half of each hinge into the aileron
slots. Slide the aileron toward the wing until
no gap remains between the aileron and the
wing.
When satisfied with the alignment, remove
the straight pins, being sure to keep the
aileron tight to the wing. You may wish to
apply a few pieces of masking tape to keep
the pieces in place.
6. Keeping the aileron and wing in position,
apply 3 or 4 drops of Instant thin CA to the
small exposed area of each hinge.
Turn the wing assembly over and again
apply 3 or 4 drops of thin CA to the exposed
hing surface.
Allow to dry for 10 minutes before flexing the
aileron.
7. Repeat the above steps for each of the other
ailerons.
NOTE: Remember that the following pictures may
not exactly match the hardware you are using.
Always check the manufacturer’s instructions when
installing radio equipment.
5. Carefully check the alignment of the aileron,
making sure it is flush with the end of the
wing.
1. Collect the following parts:
(1) Aileron servo door
(2) 3/8 x 3/4 x 3/4"servo mounting block
(4) 1/8 x 3/4 x 3/4 aileron door mounting plate
(4) Servo mounting screw (supplied with radio)
(4) #2 Washer
(4) #2 x 3/8" screw
(1) Servo with rubber grommet
Aileron Servo Installation (Bottom Wing)
4

8. Place the servo door on the wing and drill a
1/16” hole on each corner. Screw the door to
the plate, using the #2 x 3/8” screw and the
#2 washer supplied with the kit.
Repeating the above steps, mount the sec-
ond aileron servo.
3. Remove the servo from the door. Spread
epoxy on the servo mounting blocks and
glue them in place along the line just drawn,
making sure the wood grain runs vertically.
4. When the epoxy is dry, drill 1/16” holes and
mount the servo onto the blocks with the
mounting screws supplied with the radio.
Repeat these steps to mount the other
aileron servo.
2. With the servo door upside down on the
work surface, place the servo on top of the
door with the servo arm post centered verti-
cally and horizontally with the servo door
notch. Mark the location of the servo, as
above.
6. Hold one of the servo plates in place against
one corner of the servo door, locating it in
such a way that the tab does not interfere
with the servo.
Mark the servo door-edge location on the
plate.
7. CA glue the plate to the corresponding cor-
ner of the servo hole in the wing.
Follow the same procedure with each of the
other three plates.
NOTE: Plates will fit into the corner differently,
depending on the servo used.
5

Aileron Extension Installation
1. Gather the following items.
(2) 12” extension wires
NOTE: Before starting, remove the servo door and
make sure the length of one servo wire, when
plugged into the 12” extension, is long enough
to reach to the center of the wing. If necessary, add
an additional extension to reach the center of the
wing.
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 electrical tape.
2. Remove servo door and, making sure to use
the correct servo for the opening, attach the
servo wire to the12” extension and securely
tape connection.
NOTE: Before continuing, make sure the other end
of the string inside the wing, next to the second
aileron hole, is taped firmly to the wing, so that it is
not pulled out by mistake. (If it becomes necessary
to reinsert this string into the wing, tie a 6-32 nut to
the end of the string and feed it back into the wing.
The nut will easily fall through the wing rib holes.
Tie the other end of the extension to the
string that exits the servo opening and tape
this connection, also.
3. Grasping the string in the hole in the center
of the wing, SLOWLY pull until the end of the
12” extension comes out of the hole. Work
the string back and forth to get the extension
plug to go through the cutouts in each rib.
Pull gently and have patience.
4. Tape the extension securely to the wing, so
that it will not slide back in while you are
working.
Repeat these steps for the other half of the
wing, so that both servo extensions are exit-
ing the holes in the center of the wing..
Control Horn Installation
1. Collect the following items:
(2) Large control horn with back plate
(4) 2-56 x 3/4” screw
(2) 1/16 x 7” threaded wire
(2) Snap-link
(2) Nylon snap nut (molded 6-up - see photo in
Engine Pushrod Installation)
2. Replace the servo door and screw it down
onto the wing.
3. Make a mark at a 90º angle to the trailing
edge and in line with the servo arm.
6

Wing Dowel Installation
5. Thread a snap-link on the end of one of the
1/16 x 7” threaded rods.
Place the snap-link in the second-from-the-
top hole on the control horn.
6. Making sure the aileron is in neutral position,
mark where the wire meets the hole on the
servo arm.
Put a 90º bend (or a z-bend, if preferred) in
the wire, as shown above, and then attach
the wire to the servo arm with a snap nut.
Finally, put a drop of glue on the snap nut.
Repeat these steps for the other aileron.
4. Position the control horn so that the snap
link holes are right next to the hinge line.
Using a 3/32” drill bit, make a pilot hole in
each screw location, and then mount the
control horn, using the 2-56 x 3/4” screws.
1. Using epoxy, mount the 5/16 x 1-3/4” dowels
into the holes in the leading edge of the bot-
tom wing. Make sure to leave about 1/2” of
dowel sticking out of the front of the wing.
You may wish to slighly taper the exposed
dowel ends for ease of insertion into the fuse
holes.
Now set the bottom wing aside until later.
7

1. Collect the following parts.
(1) Fuselage
(1) Servo tray
(2) Front cabane doubler
(2) Cabanes
(2) Cross brace
(4) 4-40 x 1/2” Socket head screw
(4) 4-40 x 3/8” Socket head screw
(4) #4 x 7/16” washer
(4) #4 washer (smaller)
(8) 4-40 lock nut
2. Being careful to align the holes and the
servo cutouts, CA glue the servo tray dou-
bler into the fuselage.
4. Beginning at the front of the fuselage, make
a mark at 5” and at 9-3/4”. This will help
locate the pre-cut cabane slots on the
curved top of the fuse, behind the firewall.
5. Using a hobby knife, make a horizontal slit
from front to back, in the middle of the
cutout, as shown.
Slit all four cutouts in the same way.
FUSELAGE ASSEMBLY
Cabane Installation
3. Glue the front cabane doublers over the
holes in front of the fuselage former. Again,
make sure the holes in both the doubler and
the fuselage are aligned.
6. Gently push one side of the cabane into the
front fuselage slot, until it falls inside.
7. Slip the other side of the cabane into the cut
on the opposite side of the fuselage.
8

2. Locate the pre-cut hinge slots and, using a
hobby knife, make sure all slots in the stabi-
lizer, elevators, rudder, and fin are cleanly
cut.
Test the size of each slot by sliding a hinge
halfway into the opening. Then set the rud-
der and elevators aside until later.
8. Turn the fuselage over and, working from
the inside, insert a 4-40 x 1/2” screw with
a #4 x 7/16” washer into the fuselage hole in
the cabane doubler and then through the
cabane hole. This is somewhat tricky, so
have patience.
When the screw protrudes through the
cabane hole, cap it with a 4-40 locking nut
and tighten.
Repeat these steps at each of the three
mounting points to complete the cabane
installation.
9. Insert a 4-40 x 3/8” screw and washer into
the cross brace in the top side hole of the
front cabane and secure with a 4-40 locking
nut.
Then, mount the other end of the cross
brace into the rear cabane, as shown below.
Repeat with the other cross brace.
Stabilizer/Fin Installation
1. Collect the following items.
(1) Fuselage
(1) Horizontal stabilizer
(1) Vertical fin
(2) Elevators
(1) Rudder
(1) 5ft. Length of string (not included in kit)
9

3. Locate the pre-cut stab cutout by feeling
along the fuse side in the area where the
stab should go.
Remove the covering over the stab slot on
both sides of the fuselage.
4. Mark the center of the stab on both the trail-
ing and leading edge.
5. Slide the stab into the back of the fuselage,
using the center marks as a guide. Measure
the stab, as shown, to make sure it is prop-
erly centered.
NOTE: It is also possible to see the centermarks
through the fin cutout.
6. Turn the fuse around, and determine the
vertical centerline of the fuse top front.
Measure to the center point on the top of the
fuselage. DO NOT CENTER ON THE FIRE-
WALL THRUST LINE.
7. Place a pushpin on the center mark and tie
a string around the pushpin.
8. Stretch the string back until it touches the
outer tip of the stabilizer leading edge. Mark
the string and then measure back to the
other outer L.E. tip, making sure the distance
is the same.
10