GREAT PLAINS Super Kybolt User manual

WARRANTY
Great Planes Model Manufacturing Co. guarantees this kit to befreefromdefectsinboth
materialand workmanshipat thedateofpurchase.Thiswarrantydoesnot coverany
component parts damaged by use or modification. Innocase shall Great Planes' liability
exceed the original cost of the purchased kit. Further, Great Planes reserves the right to
change or modify this warrantywithoutnotice.
Inthat Great Planes has no controlover the final assembly or material used forfinal
assembly, no liability shall beassumed nor accepted forany damage resulting fromthe use by
the user of the finaluser-assembled product. Bythe act of using the user-assembled product
theuseraccepts allresultingliability.
Ifthe buyer isnotprepared to accept the liabilityassociated with theuseofthis
product, heisadvised to immediatelyreturn this kit innew and unusedcondition to the
place of purchase.
READTHROUGH THIS INSTRUCTION
BOOK FIRST.ITCONTAINS IMPORTANT
INSTRUCTIONSANDWARNINGS
CONCERNINGTHE ASSEMBLYAND
USEOF THIS MODEL.
P.O.BOX 788URBANA, ILLINOIS61801 [phone]
ENTIRE CONTENTS © Copyright 1992,HOBBICO,INC.
SKY6P03V1.1

TABLE OF CONTENTS
INTRODUCTION..........................................3
PRECAUTIONS............................................ 3
OTHER ITEMS REQUIRED.......................... 4
SUPPLIES AND TOOLS NEEDED ...............4
DECISIONS YOU MUST MAKE NOW..........5
ABBREVIATIONS ......................................... 5
TAIL FEATHERS..........................................7
BUILD THE FINAND RUDDER.................... 7
BUILD THE STABILIZER AND ELEVATORS. 8
TEMPORARILY INSTALL HINGES .............10
FUSELAGE ASSEMBLY..............................11
PREPAREFUSE SIDES...............................11
ASSEMBLE FUSELAGE.............................. 16
DRILL ENGINE MOUNT...............................16
FITFUEL TANK AND
FUELPROOF TANK COMPARTMENT......... 16
INSTALL TAIL PUSHRODS.......................... 18
SOLDERING HINTS.....................................19
ASSEMBLE THE CABANES........................ 20
SETTING THETOP WING INCIDENCE ......21
SOLDERING THE CABANE
WIRES TOGETHER.....................................22
INSTALL TOP SHEETING............................23
ATTACH THE TAIL SURFACES
TO THE FUSELAGE .................................... 26
WING ........................................................... 28
SPARS......................................................... 28
BUILD THE BOTTOM WING .......................29
BUILD THE TOP WING................................31
JOIN THE TWO TOP WING HALVES ..........33
INSTALL THE TOP WING SHEETING .........37
FINISHTHE TOPWING...............................42
BUILD THE INTERPLANE STRUTS ............ 44
JOIN AND SHEET THE BOTTOM WING ....46
FINISHTHE BOTTOM WING.......................49
FINISH AND ATTACH THE WING................55
FINAL ASSEMBLY......................................57
BUILD THE BOTTOMWING FAIRING......... 57
INSTALL THE LANDING GEAR ................... 58
ASSEMBLETHECOWL..............................59
PREPARE THE CANOPY ............................ 62
INSTALL THE CONTROL HORNS............... 62
MAKE THE TOP WING LOCK...................... 63
BALANCE THE AIRPLANE LATERALLY...... 63
FINAL SANDING..........................................64
COVERING.................................................. 64
GLUE THE AILERON HINGES....................64
GLUE ELEVATOR AND RUDDER HINGES. 64
GLUE CANOPY INPLACE ..........................64
ASSEMBLE WHEEL PANTS........................65
STRENGTHEN AND FUEL PROOF ............66
WING SEATING........................................... 67
FINAL HOOK-UPS.......................................67
CONTROL THROWS....................................68
BALANCE YOUR MODEL............................68
FINAL CHECKS...........................................68
PRE-FLIGHT................................................69
CHARGE THE BATTERIES.......................... 69
FIND A SAFE PLACE TO FLY......................69
GROUND CHECK THE MODEL .................. 69
RANGE CHECK YOUR RADIO.................... 70
ENGINE SAFETY PRECAUTIONS .............. 70
AMA SAFETY CODE...................................70
FLYING........................................................71
2-VIEW DRAWING.......................................72
Metric Conversion Chart
Inchesx 25.4= mm(conversion factor)
1/64"= .4mm
1/32"= .8mm
1/16" = 1.6mm
3/32" = 2.4mm
1/8"= 3.2 mm
5/32" = 4 mm
3/16" = 4.8mm
1/4"= 6.4 mm
3/8" = 9.5 mm
1/2"= 12.7mm
5/8"= 15.9mm
3/4" = 19mm
1"= 25.4mm
2" = 50.8 mm
3"= 76.2 mm
6" = 152.4mm
12" = 304.8mm
15" = 381 mm
18"= 457.2mm
21" = 533.4mm
24" = 609.6 mm
30" = 762 mm
36" = 914.4mm
-2-

WARNING! THISISNOTA TOY!
THIS ISNOTA BEGINNER'S AIRPLANE!
This R/C kitand the model you willbuildisnot a toy!Itiscapable of serious bodily harm and
property damage ITISYOUR RESPONSIBILITY AND YOURS ALONE — to build this kit correctly, to
properly install allR/C components andflyinggear (engine, tank, pushrods, etc)and to test the model
and flyit only with experienced, competent help, using common sense and inaccordance with allsafety
standards asset down inthe Academy of Model Aeronautics Safety Code Itissuggested that you join
the AMAand become properlyinsuredbeforeyouattemptto flythismodel IFYOU AREJUST
STARTING R/C MODELING, CONSULT YOUR LOCAL HOBBY SHOPOR WRITE TO THE ACADEMY
OF MODEL AERONAUTICS TOFINDAN EXPERIENCED INSTRUCTORINYOUR AREA.
Academy of Model Aeronautics
1810 Samuel Morse Dr.
Reston,VA22090 [phone]
INTRODUCTION
Congratulationsandthankyoufor
purchasing the Great Planes SUPER SKYBOLT'
The skyboltincorporatesseveralnew design
features never beforefound ina biplane kit The
revolutionarywingattachmentsystemmakes it
incredibly easy toassemble and disassemble at
the field using only a screwdriverItalso features
several new constructiontechniques that make it
the easiest and straightest building biplane ever!
The Great Planes Super Skybolt is a high
performance biplane that ismodeled after the full
size Skybolt Itnot only looks beautiful,but it is
also thesmoothestand most predictable flying
biplane we have ever flownHowever, this isnot
abeginner's airplane! While the Super Skybolt
is not difficulttobuild and fliesgreat,we must
discourageyoufromselectingthiskit as your
firstR/C airplane Itis highly maneuverable, and
lacks theself-recoverycharacteristicsof a good
basictrainersuchastheGreatPlanesPT
Series airplanes On the other hand, ifyouare
confidentwithyourflyingskilland can safely
handleaileronairplanessuchastheGreat
Planes Ultra-Sport Series or Big Stick Series,
the Super Skybolt isan excellent choice Ifyou
currentlyflyan aileronairplane,but youare
unsureabout yourabilitytohandle theSuper
Skybolt, we recommend that you buildand flya
low-wing sport plane first.
Please inspect allparts carefully before
starting to build!Ifany parts are missing,
broken or defective, or ifyou have any
questions about building or flyingthis
airplane,pleasecallusat [phone]
and we'llbe gladtohelp. If youare
callingfor replacement parts, pleaselook
up thepartnumbersandthekit
identification number (stamped on the
endof the carton) and have them ready
when calling.
PRECAUTIONS
1You must build the plane according to the
plans and instructions. Do not alter or modify
the model, as doing so may result inan unsafeor
unflyablemodel Ina fewcasestheplans and
instructions may differslightly fromthe photos In
thoseinstancesyoushouldassumetheplans
and writteninstructionsarecorrectAlso,you
may notice a slight differenceinlength between
longer parts and the plans This isnormal and is
caused by the plans expanding and shrinking with
the changing moisturecontent inthe air Donot
modify the parts to fitthe plan
2You musttake time to buildstraight, true and
strongIMPORTANT- Glueshouldneverbe
substitutedfora good-fittingjointTake a little
extratime toget a good fittingjointand glue it
properlyItwillbe stronger,neater,and much
lighter than a bad joint heldtogether with a glob
of glue!
3-

3You must use a proper R/C radio that isinfirst
class condition and meets the currentAMAand FCC
requirements and the requirements of your local flying
club,thecorrectsizedengineand correct
components (fueltank, wheels, etc.).
4You mustproperlyinstallallR/Candother
components so that the model operates properly on
the ground and inthe air.
5.You must test the operation of the model before the
firstandeachsuccessiveflighttoinsurethatall
equipment is operating,and youmust make certain
that the model has remained structurally sound.
6You must fly the model onlywith thecompetent
help of a wellexperiencedR/C pilot if youare not
already an experienced and knowledgeable R/C pilot
atthis time.
Note: We, as the kit manufacturer, provide
you with a top quality kit and great
instructions, but ultimately the quality and
flyability of your finished model depends on
how you build it; therefore, we cannot in any
way guarantee the performance of your
completedmodel, andnorepresentationsare
expressed or implied as to the performance
or safety of your completed model.
Remember: Take your timeand follow directions
to end upwith a well-built model that isstraight
and true.
OTHER ITEMS REQUIRED
DFour-channel radio with 4 or 5 servos
DPropellers (Top Flite® Power Point™ recommended
-see engine instructions for recommended sizes)
D2-1/2"(63 5mm)Spinner
D14oz Fuel Tank
DIron-on Covering Material (TopFlite MonoKote®
recommended)
DFuelproof Paint forwheel pants and cowl
NOTE Top Flite has paint available that matches
Super MonoKote, andisavailable inconvenient
spray cans
DSilicone Fuel Tubing
D1/16" (1 5mm) thick Wing Seating Tape
DLatexFoamRubberPadding(Hobbico®1/4"
recommended )
DPlasticPilot: Williams Bros. #185 Sport 2-1/2"
Scale
D2-3/4" (70mm) Main Wheels
D1-1/4"(32mm)TailWheel
D22 Hinges*
D2 - Servoextensions(each24"long)req. for
ailerons on both wings
D3/32"(2 5mm)WheelCollars - 2 required fortail
wheel
D#64 RubberBands
*NOTE: There are many types of good hinges on the
market, and everyone has their personal preferences;
therefore, hinges have not been included in this kit.
The current favorite of many modelers is the
laminated hinge that permits hinge slotting with a
hobby knife, and gluing with thin CA adhesive.
-4
SUPPLIES ANDTOOLS NEEDED
D2 oz Thin CA Adhesive
D2 oz Medium or Thick CA Adhesive
D2 5 oz 15-Minute Epoxy
DHand or Electric Drill
DDrill Bits 1/16, 3/32", 5/32", 3/16", 1/4", & 19/64"
DSealing Iron (Hobbico or Top Flite recommended)
DHeat Gun (Hobbico or Top Flite recommended)
DRazor Saw
DHobby Knife, #11Blades
DPliers
DScrew Drivers
DT-Pins
DStraightedge
DMaskingand/orStrappingTape (Requiredfor
construction)
DSandpaper (coarse, medium, fine grit)*
DT-Bar Sanding Block (or similar)
DWaxed Paper
DLightweightBalsa Filler ( Hobbico HobbyLite™
recommended)
DPetroleum Jelly (Vaseline)
DIsopropyI Rubbing Alcohol(70%)
DSpray Adhesive (optional) (3M "77")
DDremel Moto Tool or similar (optional)
*NOTE: On our workbench, we have four 11" T-Bar
sanders, equipped with #50,#80, #700 and #150-grit
We also keep some #320-
grit wet-or-dry sandpaper handy for finish sanding
before covering.

DECISIONS YOU MUST MAKE NOW
ENGINEAND MOUNT
The recommendedenginefortheSUPER
SKYBOLT isa 61* - 90 cubic inch (10 - 15cc)
displacement 2-cycle or a 90 - 1 20 cubic inch
(15-20cc)displacement4-cycleThe
instructionsandplansshowan OS Max
61(10cc)SF and an OS Max1 20 (20cc)
Surpassbeing installedItyouareusing an
engineotherthanoneofthese,be sureto
doublecheck all measurements before gluing or
cutting things that have to dowith the engine.
*NOTE: Performance may bemarginal ifa non-
Schnuerle-ported.60 cu.in. 2-Cycleengine
isused
This kitincludes a new Great Planesadjustable
.40- .70engine mount (EM4070) that fitsmost
40 - 61(2-Cycle)engines and 40 - 70 (4-cycle)
engines Ifthe supplied mount does not fityour
engine,it may be necessarytopurchasea
different mount (check with your hobbydealer).
POSSIBLE RADIO
INSTALLATIONS
The Super Skybolt can utilize either one
or twoaileron servosWe recommend that you
use twoaileron servos and build the top wing
withaileronsThis is the most maneuverable
configurationand you can always reduce the
controlthrowstoachievethesensitivityyou
desireWhenusingtwoaileronservos,the
servos are mounted inthe bottom wing, directly
in frontoftheaileronsandcontrolslopis
virtuallyeliminatedIf youprefertouse only
one aileronservo,we suggest that youdo not
put ailerons on the top wingdue to the inherent
top aileronsloppiness The plans show both
methods of construction.
COMMON ABBREVIATIONS USED
INTHIS BOOK AND ONTHE
PLANS:
GETREADY TO BUILD
Elev= Elevator
Fuse= Fuselage
LE= Leading Edge(front)
LG= LandingGear
Ply= Plywood
Stab= Stabilizer
TE = Trailing Edge(rear)
"= Inches
Tri= Triangle
TYPES OFWOOD
D1 Unrollthe plansheets andrerollthem inside
outto helpthem lieflat.
D2 Remove allparts fromthe box Asyou do,
determine the name of each partbycomparing it
with the plan and the parts listatthe back of this
book. Using a felttippen, writethe partname or
size on each piece to avoid confusionlater Use
thedie-cutpartpatternsshownon page 6 to
identify the die-cut parts and mark them before
punching out Save allleftover pieces. Ifany of
the die-cut parts are difficult to punch out, do not
forcethem' Instead, firstcut around the parts with
ahobby knife Afterpunching out the die-cut parts,
use your T-Bar or sanding blockto lightly sand the
edges to remove any die-cutting irregularities.
BALSA BASSWOOD
PLYWOOD
D3 As you identify andmark the parts, separate
them into groups, such as fuse (fuselage), wing,
finandstab (stabilizer), and hardware.
-5-

-6-
DIE-CUT PATTERNS

TAIL FEATHERS
BUILD THE FINAND RUDDER
D1.Tapethe fuselage sideview portion of the
plan downontoyourflatworksurfaceTape a
piece ofwaxedpaper overthefinand rudder
portion of the plan.D5 Using the plan as a guide, cut 3 pieces of
1/16" x 3" balsa froma 1/16" x 3" x 24" balsa
sheet(SKY6S06)toformthefinsheeting as
shownin thephotoGlue thesetogetherand
quickly wipe off any excess glue with a papertowel
before itcures Sand both sides smooth and then
cutand sand the correct angle into the bottom of
the sheeting so you don't have to cut itafter it's
installed on the fin Make sheeting forboth sides of
the fin.
HINT:Use new, sharp sandpaper when sanding
wood with glue joints initThe sharper grit will cut
through the glue much easier and produce better
results than worn out sandpaper
D2 Working over the plan,cut andassemble the
fin andrudder framework using the die-cut 3/16"
balsafinandrudderparts(SKY6S01and
SKY6S02) and the 3/16" x 3/4" x 24" balsa sticks
(SKY6S05)as shown inthe photo Sort through
the 3/16" x 3/4" x 24" balsa sticksand pick the
hardest twoUse the hardest one later forthe
stab trailing edge and use the next hardest one
here for the fintrailing edge Pinthe parts inplace
overtheplanas youassemblethem,but be
careful you don't glue the rudder to the fin
D6 Glue the sheetingto one side ofthefin.
Notice that the grain runs vertical on the fin.
Keep the finflat while attaching the sheeting After
the side sheeting isinstalled, trim itflush with the
leadingand trailing edges of the finNOTE: Donot
cutthroughthesheetingandintothe
framework. Always cut into the work surface'
D3.Cut the fin and rudder "ribs" from the 3/16" x
1/4" x 24" balsasticks (SKY6S04).Gluethese in
placewith CA.
D4. Sand bothsidesofthefinand rudder
smooth with a fine grit sandingblock.
D7 Gluethe other sidesheeting inplaceBesure
the fin iskeptflat untilthe glue cures Trim andsand
the sheetingflushwiththeleading and trailing
edgesoftheframeworkCarveand sandthe
leadingedgeto a nicerounded shape asshown on
theplans,butkeepthetrailingedgesquare.
-7-

D8.Draw a centerline allaround the edges of the
rudder. Sand the rudder to a taper as shown on
the fuselagetopview.Theframeworkshould
end up approximately3/32"thickat thetrailing
edge. Refer to the centerline you drew to keep the
rudder symmetrical.
D12. Cut two4" long pieces of 1/16"x 1-3/8"
balsa sheeting fromthe 1/16" x 1-3/8" x 24" hard
balsa sheeting(SKY6S07).Glue thesetoboth
sidesof the rudder next to the sheeting on R6.
D9.Using the plan asa guide, cut a 1/16" x 3" x
24" balsa sheet(SKY6S06)in half toformthe
rudder sheetingas shownin thephoto.Glue
these together andsand both sides smooth. Make
sheeting forboth sides of the rudder. Cut one end
of the sheeting perpendicular to a long edge.D13.Usea sanding block with medium (150) grit
sandpapertosandbothsidesoftherudder
smooth. Carve and sand the rudder trailing edge to
anice rounded shape and the leading edge to a
"V" shape asshown on the plan.
D10.Glue the sheeting to one side of the rudder
so theperpendicular edge overlapsonto R6
approximately 1/8". The rest of R6 isnot sheeted
until later. Keep the rudder flat while attaching the
sheeting. Afterthe sheeting isinstalled, trim itflush
with the outside edges of the framework.
D11.Glue the other sidesheeting inplaceso that
ittoo only overlaps approximately 1/8"onto R6. Be
sure the rudder iskept flatuntil the glue cures.
Trimandsand the sheeting flush with the leading
andtrailing edges of the framework.
BUILD THE STABILIZER AND
ELEVATORS
D1.Tapethe fuselage topview portion of the
plandown onto your flatwork surface, and cover
the stabilizer portion of the fuselage top view with
waxpaper.
D2.Assemble the stab and elevator framework
over the plan,using the die-cut 3/16" balsa stab
-8-

parts (SKY6S02 and SKY6S03) andthe 3/16" x
3/4"x 24"balsasticks(SKY6S05)Use the
hardest 3/16" x 3/4" stick forthe stab trailing edge
Pin thepartsin placeovertheplanasyou
assemblethembut be carefulnot toglue the
elevator to the stab
D7 Glue the other side sheeting inplace Be
sure the stab iskept flatuntil the glue cures Trim
and sand the sheeting flush with the leading and
trailingedgesoftheframeworkNOTE:It is
essential to get a strong and complete bond
betweenthestabsheetingandthestab
framework, especially inthe center, therefore,
we recommend using 30minute epoxy when you
apply the lastpiece of sheeting Spread the epoxy
evenlybut sparinglyon the structure,to avoid
excess weight
D3 Cut the stab and elevator"ribs"fromthe
3/16"x 1/4" x 24" balsa sticks (SKY6S04) Glue
these inplace with CA.
D4 Use a sanding blockwith medium (150) grit
sandpaper to sand the edges and both sides of
the stab and elevatorsmoothCarefullydraw a
centerline all around the edges of the stab and
elevatorThiswillmakeit easiertomaintain
symmetry when sanding later.
D8 Carve andsand the leadingedge to a nice
rounded shape as shown on the plans, butkeep
the trailing edge and the tips square
D5 Glue two 1/16" x 3" x 24" balsa sheets
(SKY6S06) together(edge to edge) to formone
piece of stab sheeting Sand or trimthe edge of
the sheetsbeforegluingto obtaina goodjoint
between the two, without any gaps Afterthe glue
iscured, sand both sides of thesheetingwitha
finegritsandingblock Make sheetingforboth
sides of the stab.
D9 Usinga sandingblockandcoarse (80-grit)
sandpaper, sand both sides of the elevators to a
taper (see crosssectionon plans) The trailing
edgeshould endupapproximately 3/32" wide
D6 Thoroughly glue the sheeting to one side of
the stab Keep the stab flatwhileattachingthe
sheeting Afterthe sheeting isinstalled, trim itflush
with theedgesof the stab.
D10Cut four 1/16" x 2-5/8" x 24" balsa sheets
(SKY6S08) inhalfto formeight 12" long pieces
Glue these 12sheets together to formfour 5-1/4"
wide sheetsCut one end of each sheet so itis
perpendicular to the long edges Sand both sides
of these sheets smooth.
-9

TEMPORARILY INSTALL HINGES
D1 Using the plan as a guide, mark the hinge
locationson the stab,elevators,finand rudder
Designate one side of the stabas beingthe top and
oneelevator as being"right"andthe other as"left".
D11Glue one 5-1/4" sheet to each elevator at
the angle shown on the plans and inthe photo so it
overlaps onto S-6 approximately 1/8" Cut a corner
off the unused end of the sheet, and glue itat the
front tip of the elevator Trim the sheetingflush with
the edges of each elevator.
D12Glue the remaining sheeting inplace on the
other side of each elevator so that ittoo overlaps
onlyapproximately1/8" ontoS-6Be surethe
elevator iskept flat until the glue cures Trim and
sandthesheetingflushwiththeedgesof
the framework
CAUTION!!!: You must useextreme care
whencuttinghinge slotswitha hobby
knife,toavoidcuttingyourself!If the
balsa part breaks while you are pushing
on the knife, the blade could go into your
handbeforeyouknowit!A good
precaution isto wear leather gloves while
performing the following steps.
D13Cut four4" long pieces of 1/16" x 1-3/8"
balsa sheetingfromwhatis leftofthe1/16"x
1-3/8"x 24" hard balsa sheeting (SKY6S07) Glue
these to both sides of each elevator, next to the
sheeting that stops atS-6
D14 Sand the leading edge of the elevators to a
"V-shape" as shown on the plan Round off the
tips and the trailing edge, but keep the inside edge
(markedwith anarrow) square
D2 Cut thehinge slotson thecenterlinesyou
drew earlierOur recommendedhinge slotting
method isdescribed below.
ABegin by carefully cutting a very shallow slitat
the hinge location The firstcut isto establish
yourcut in the right place, so concentrateon
staying on the line and don't cut too deeply.
BMake three or four more cuts inthe same line,
going slightly deepereach time. As you make
theseadditional cuts,workon going straight
intothewoodContinuethisprocesswhile
"wiggling"theknifehandleforwardand
backwarduntilthebladehas reachedthe
proper depth forthe hinge
C.Trial fitthe hinge into the slot Ifthe hinge is
difficult to push in, re-insert the knife and move
it back andforthin theslota fewtimesto
enlargethe slot Donotgluethe hingesyet.
10