GREAT PLANES Cherokee .40 ARF User manual

INSTRUCTION MANUAL
Wingspan: 60 in [1520mm]
Wing Area: 606 in2[39dm2]
Weight: 6.75 – 7.25 lb [3060 – 3290g]
Wing Loading: 26 – 28 oz/ft2[79 – 85g/dm2]
Length: 46 in [1170mm]
Radio: 4-channel minimum with four to seven
standard servos and standard size receiver
Engine: .40 – .46 cu in [7 – 7.5cc] two-stroke,
.56 cu in [9.2cc] four-stroke,
42-50-800kV brushless out-runner motor
WARRANTY
GreatPlanes®ModelManufacturingCo.guaranteesthiskittobefreefromdefectsinbothmaterialandworkmanshipatthedateofpurchase.
This warranty does not cover any component parts damaged by use or modification. In no case shall Great Planes’ liability exceed the
original cost of the purchased kit. Further, Great Planes reserves the right to change or modify this warranty without notice.
In that Great Planes has no control over the final assembly or material used for final assembly, no liability shall be assumed nor accepted
for any damage resulting from the use by the user of the final user-assembled product.By the act of using the user-assembled product,
the user accepts all resulting liability.
If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised to return this kit
immediately in new and unused condition to the place of purchase.
To make a warranty claim send the defective part or item to Hobby Services at the address below:
Hobby Services
3002 N. Apollo Dr., Suite 1
Champaign, IL 61822 USA
Include a letter stating your name, return shipping address, as much contact information as possible (daytime telephone number, fax
number, e-mail address), a detailed description of the problem and a photocopy of the purchase receipt. Upon receipt of the package
the problem will be evaluated as quickly as possible.
READ THROUGH THIS MANUAL BEFORE
STARTING CONSTRUCTION. IT CONTAINS
IMPORTANT INSTRUCTIONS AND WARNINGS
CONCERNING THE ASSEMBLY AND USE OF
THIS MODEL.
Champaign, Illinois
[phone], Ext 5
airsuppor[email protected]
Entire Contents © Copyright 2008 GPMZ1033 for GPMA1033 V1.0

2
TABLE OF CONTENTS
INTRODUCTION................................................................................2
AMA ...................................................................................................2
SAFETY PRECAUTIONS ..................................................................2
DECISIONSYOU MUST MAKE.........................................................3
Radio Equipment..........................................................................3
Power System Recommendations...............................................3
Propeller.......................................................................................4
Batteries & Charger......................................................................4
ADDITIONAL ITEMS REQUIRED .....................................................4
Required Hardware & Accessories..............................................4
Adhesives & Building Supplies.....................................................4
Optional Supplies & Tools ............................................................4
BUILDING STAND.............................................................................5
IMPORTANT BUILDING NOTES.......................................................5
ORDERING REPLACEMENT PARTS...............................................5
COMMON ABBREVIATIONS ............................................................6
METRIC CONVERSIONS..................................................................6
METRIC/INCH RULER.......................................................................6
KIT INSPECTION...............................................................................7
KIT CONTENTS.................................................................................7
PREPARATIONS................................................................................8
BUILDTHE WING PANELS...............................................................8
Install the Aileron & Flap Servos & Pushrods ..............................8
Fixed Flaps.................................................................................11
BUILDTHE FUSELAGE .................................................................11
Install the Tail Surfaces...............................................................11
Install the Tail Servos & Pushrods..............................................12
Glow Engine Installation.............................................................13
Brushless Motor Installation.......................................................16
Assemble & Install the Landing Gear.........................................18
FINISHTHE MODEL........................................................................20
Install the Receiver.....................................................................20
Install the Cowl, Spinner & Propeller..........................................21
Install the Wing & Canopy Hatch................................................22
Apply the Decals........................................................................22
GETTHE MODEL READYTO FLY..................................................22
Install and Operate the Motor Battery (Brushless Only).............22
Battery Precautions/Connecting Batteries .................................23
Check the Control Directions .....................................................23
Set the Control Throws...............................................................23
Balance the Model (C.G.)...........................................................24
Balance the Model Laterally.......................................................25
PREFLIGHT.....................................................................................25
IdentifyYour Model.....................................................................25
Charge the Batteries..................................................................25
Balance Propellers.....................................................................25
Ground Check............................................................................25
Range Check .............................................................................25
ENGINE SAFETY PRECAUTIONS..................................................26
LITHIUM BATTERY HANDLING & USAGE ....................................26
AMA SAFETY CODE (excerpts).....................................................26
CHECK LIST....................................................................................27
FLYING.............................................................................................27
Fuel Mixture Adjustments...........................................................27
Takeoff........................................................................................27
Flight ..................................................................Back Cover Page
Landing ..............................................................Back Cover Page
Flaps ..................................................................Back Cover Page
INTRODUCTION
Congratulations on your purchase of the Great Planes
Cherokee .40 ARF! We have designed this plane to be a
quick, fuss-free build by minimizing the amount of glue and
measuring that needs to be done for a typical ARF. With a
bolt-on, self-aligning tail section along with many other small
time-consuming tasks already complete, you can have your
Cherokee .40 ARF built in as little as 4 to 6 hours. Just like
its full-scale counterpart, the Cherokee .40 ARF is extremely
easy to fly and would be appropriate for beginners who
have mastered a trainer or for the veteran pilot who just
appreciates the rich history of the Cherokee.
For the latest technical updates or manual corrections to
the Cherokee .40 ARF visit the Great Planes web site at
www.greatplanes.com. Open the “Airplanes” link, then
select the Cherokee .40 ARF. If there is new technical
information or changes to this model, a “tech notice” box will
appear in the upper left corner of the page.
AMA
We urge you to join the AMA(Academy ofModel Aeronautics)
and a local R/C club.The AMA is the governing body of model
aviation and membership is required to fly at AMA clubs.
Though joining the AMA provides many benefits, one of the
primary reasons to join is liability protection. Coverage is not
limited to flying at contests or on the club field.It even applies
to flying at public demonstrations and air shows. Failure to
comply with the Safety Code (excerpts printed in the back of
the manual) may endanger insurance coverage. Additionally,
training programs and instructors are available at AMA club
sites to help you get started the right way. There are over
2,500 AMA chartered clubs across the country. Contact the
AMA at the address or toll-free phone number below:
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302-9252
Tele. [phone]
Fax [phone]
Or via the Internet at:
http://www.modelaircraft.org
IMPORTANT!!! Two of the most important things you can do
to preserve the radio controlled aircraft hobby are to avoid
flying near full-scale aircraft and avoid flying near or over
groups of people.
PROTECTYOUR MODEL,YOURSELF
& OTHERS....FOLLOWTHESE
IMPORTANT SAFETY PRECAUTIONS
1.Your Cherokee .40 ARF should not be considered a toy,
but rather a sophisticated, working model that functions very
much like a full-size airplane. Because of its performance
capabilities, the Cherokee .40 ARF, if not assembled and
operated correctly, could possibly cause injury to yourself or
spectators and damage to property.
2.Youmustassemblethemodelaccording to the instructions.
Do not alter or modify the model, as doing so may result in an
unsafe or unflyable model. In a few cases the instructions may
differ slightly from the photos. In those instances the written
instructions should be considered as correct.

3
3.You must take time to build straight, true and strong.
4. You must use an R/C radio system that is in first-class
condition, and a correctly sized engine and components
throughout the building process.
5. You must correctly install all R/C and other components
so that the model operates correctly on the ground and in
the air.
6.You must check the operation of the model before every
flight to insure that all equipment is operating and that the
model has remained structurally sound. Be sure to check
clevises or other connectors often and replace them if they
show any signs of wear or fatigue.
7. If you are not an experienced pilot or have not flown
this type of model before, we recommend that you get the
assistance of an experienced pilot in your R/C club for
your first flights. If you’re not a member of a club, your local
hobby shop has information about clubs in your area whose
membership includes experienced pilots.
8.While this kit has been flight tested to exceed normal use,
if the plane will be used for extremely high stress flying, such
asracing,orifanenginelargerthanoneintherecommended
range is used, the modeler is responsible for taking steps to
reinforce the high stress points and/or substituting hardware
more suitable for the increased stress.
9. WARNING: The cowl and wheel pants included in this kit
are made of fiberglass, the fibers of which may cause eye,
skin and respiratory tract irritation. Never blow into a part
to remove fiberglass dust, as the dust will blow back into
your eyes.Always wear safety goggles, a particle mask and
rubber gloves when grinding, drilling and sanding fiberglass
parts.Vacuum the parts and the work area thoroughly after
working with fiberglass parts.
We, as the kit manufacturer, provide you with a top quality,
thoroughly tested kit and 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 completed model,
and no representations are expressed or implied as to the
performance or safety of your completed model.
Remember:Take your time and follow the instructions to
end up with a well-built model that is straight and true.
DECISIONSYOU MUST MAKE
This is a partial list of items required to finish the Cherokee
.40 ARF that may require planning or decision making before
starting to build.Order numbers are provided in parentheses.
Radio Equipment
The Cherokee .40 ARF requires a minimum 4-channel radio
system with four to seven 44 oz.-in. [3.2 kg-cm] minimum
standard servos. Operational flaps will require six servos.
If you are installing a glow engine, an additional standard
servo is required for the throttle.
In addition, two 9" [229mm] servo extensions are required
for the aileron servos. If you are using a radio system that
does not support mixing functions, twoY-harnesses will also
be required to connect the aileron servos and flap servos to
the receiver.
Achargejackreceptacleisoptional,butisusefulforrecharging
the receiver pack without removing the canopy hatch and
is shown in the assembly of the plane. Recommended part
numbers for the radio components are provided below:
❏Futaba®S3003 Servo Standard (FUTM0031)
❏Futaba S9001 Servo Aircraft Coreless BB
(optional, FUTM0075)
❏Futaba 9" Servo Extension J (FUTM3910)
❏Futaba 6" Dual Servo Extension J (FUTM4130)
❏Ernst Charge Receptacle Futaba J FM (ERNM3001)
Power System Recommendations
The recommended engine/motor size for the Cherokee .40
ARF is a .40 to .46 cu in [7 to 7.5cc] two-stroke engine, .56
cu in [9.2cc] four-stroke engine, or a RimFire™42-50-800kV
brushless out-runner motor. If installing a two-stroke glow
engine, a Pitts muffler is recommended. The stock muffler
can also be used with a muffler extension but additional
modification to the fuselage and cowl would be necessary.
Engine and motor order numbers are provided below:
❏O.S.®.46 AX ABL w/Muffler (OSMG0547)
❏Bisson O.S. .46 SF/FX .50 SX Pitts Muffler (BISG4046)
❏O.S. Muffler Extension #873 (OSMG2578) (Stock
muffler only)
❏Great Planes RimFire 42-50-800 out-runner
brushless (GPMG4700)
❏Great Planes Brushless Motor Mount Medium
Motors (GPMG1255)

If using the recommended brushless motor, a 60A brushless
ESC is required:
❏Great Planes Silver Series 60A brushless ESC high
volt (GPMM1850)
Propeller
If you are installing a glow engine, choose a prop based
on the engine manufacturer’s recommendation. If you are
installing the recommended RimFire brushless motor, we
suggest a 10" x 5 E or 11" x 5.5 E APC propeller.The 10" x 5 E
prop provides adequate power with a longer flight time.The
11" x 5.5 E provides excellent power for the Cherokee .40
ARF at the cost of a shorter flight time.
❏APC 10" x 5 electric propeller (APCQ4120)
❏APC 11" x 5.5 electric propeller (APCQ1055)
Batteries & Charger
For a brushless motor installation, one 3200mAh 11.1V
LiPo battery pack and one 3200mAh 7.4V LiPo battery pack
connected in series are recommended. Order numbers for
the battery packs and series connector are provided below:
❏Great Planes LiPo 7.4V 3200mAh 20C discharge
w/balance (GPMP0622)
❏Great Planes LiPo 3200mAh 11.1V 20C discharge
w/balance (GPMP0623)
❏Great Planes Series Deans®U 2 to 1 adapter (GPMM3143)
A cell balancer is required for the LiPo battery packs
listed above:
❏Great Planes ElectriFly Equinox™LiPo cell balancer
1to 5 (GPMM3160)
A suitable charger is also required. The Great Planes
PolyCharge4™is designed for LiPo packs only; however, it
is able to charge four LiPo packs simultaneously. The Great
Planes Triton2™charger will only charge one pack at a time;
however, it is capable of charging NiCd, NiMH, LiPo, and lead
acid batteries.Order numbers for both are provided below:
❏Great Planes PolyCharge4 DC only 4 output LiPo
charger (GPMM3015)
-or-
❏Great Planes ElectriFly Triton2 DC comp peak
charger (GPMM3153)
ADDITIONAL ITEMS REQUIRED
Required Hardware & Accessories
This is the list of hardware and accessories required to
finish the Cherokee .40 ARF. Order numbers are provided
in parentheses:
❏R/C foam rubber 1/4" [6mm] (HCAQ1000)
❏3' [900mm] standard silicone fuel tubing (GPMQ4131)
(glow engine installation only)
Adhesives & Building Supplies
This is the list of Adhesives and Building Supplies that are
required to finish the Cherokee .40 ARF:
❏1/2 oz. [15g] Thin Pro CA (GPMR6001)
❏Pro™30-minute epoxy (GPMR6047)
❏Masking tape (TOPR8018)
❏Threadlocker threadlocking cement (GPMR6060)
❏Denatured alcohol (for epoxy clean up)
❏Drill bits: 1/16" [1.6mm], 5/64" [2mm], 3/32" [2.4mm],
3/16" [4.8mm]
❏Dead Center™engine mount hole locator (GPMR8130)
(glow engine installation only)
❏Great Planes tap & drill set 6-32 (GPMR8102) (glow
engine installation only)
❏Tap handle (GPMR8120) (glow engine installation only)
❏Small metal file
❏#1 Hobby knife (HCAR0105)
❏#11 Blades (5-pack, HCAR0211)
❏Medium T-pins (100, HCAR5150)
❏Top Flite®MonoKote®sealing iron (TOPR2100)
❏Top Flite Hot Sock™iron cover (TOPR2175)
❏220-grit Sandpaper (glow engine installation only)
❏GreatPlanesVelcroHook&Loop1"x6"(2)(GPMQ4480)
(brushless installation only)
❏Panel line pen (TOPQ2510)
Optional Supplies &Tools
Here is a list of optional tools that will help you build the
Cherokee .40 ARF:
❏1/2 oz. [15g] Thick Pro CA- (GPMR6013)
❏2 oz. [57g] Spray CA activator (GPMR6035)
❏4 oz. [113g] Aerosol CA activator (GPMR6034)
❏CA applicator tips (HCAR3780)
❏CA debonder (GPMR6039)
❏Pro 6-minute epoxy (GPMR6045)
❏Epoxy brushes 6, (GPMR8060)
❏Mixing sticks (GPMR8055)
❏Mixing cups (GPMR8056)
4

5
❏Pliers with wire cutter (HCAR0630)
❏Hobbico Duster™can of compressed air (HCAR5500)
❏Switch & Charge jack mounting set (GPMM1000)
❏Rotary tool such as Dremel®
❏Rotary tool reinforced cut-off wheel (GPMR8020)
❏Servo horn drill (HCAR0698)
❏Hobby Heat™micro torch II (HCAR0755)
❏Precision magnetic prop balancer (TOPQ5700)
❏AccuThrow™deflection gauge (GPMR2405)
❏C.G. Machine™(GPMR2400)
❏Hobbico flexible 18" ruler stainless steel (HCAR0460)
❏Top Flite MonoKote trim seal iron (TOPR2200)
❏Top Flite MonoKote heat gun (TOPR2000)
❏Hobbico pin vise 1/16" collet w/6 Bits (HCAR0696)
❏Hobbico 8-piece ball tip hex L wrench SAE (HCAR0520)
❏Hobbico 7-piece ball tip hex L wrench Metric (HCAR0521)
❏Great Planes clevis installation tool (GPMR8030)
BUILDING STAND
A building stand or cradle comes in handy during the build.
We use the Robart Super Stand II (ROBP1402) for all our
projects in R&D, and it can be seen in pictures throughout
this manual.
IMPORTANT BUILDING NOTES
• When you see the term test fit in the instructions, it
means that you should first position the part on the assembly
without using any glue, then slightly modify or custom fit
the part as necessary for the best fit.
• Whenever the term glue is written you should rely upon
your experience to decide what type of glue to use. When
a specific type of adhesive works best for that step, the
instructions will make a recommendation.
• Whenever just epoxy is specified you may use either
30-minute (or 45-minute) epoxy or 6-minute epoxy. When
30-minute epoxy is specified it is highly recommended that
you use only 30-minute (or 45-minute) epoxy, because you
will need the working time and/or the additional strength.
• Photos and sketches are placed before the step they
refer to. Frequently you can study photos in following steps
to get another view of the same parts.
• The stabilizer and wing incidences and engine thrust
angles have been factory-built into this model. However,
some technically-minded modelers may wish to check these
measurements anyway.To view this information visit the web
site at www.greatplanes.com and click on“Technical Data.”
Due to manufacturing tolerances which will have little or no
effect on the way your model will fly, please expect slight
deviations between your model and the published values.
ORDERING REPLACEMENT PARTS
ReplacementpartsfortheGreatPlanesCherokee.40ARFare
available using the order numbers in the Replacement Parts
List that follows.The fastest, most economical service can be
provided by your hobby dealer or mail-order company.
To locate a hobby dealer, visit the Hobbico web site at
www.hobbico.com. Choose “Where to Buy” at the
bottom of the menu on the left side of the page. Follow the
instructions provided on the page to locate a U.S., Canadian
or International dealer.
Parts may also be ordered directly from Hobby Services by
calling [phone], or via facsimile at [phone],
but full retail prices and shipping and handling charges will
apply. Illinois and Nevada residents will also be charged
sales tax. If ordering via fax, include a Visa®or MasterCard®
number and expiration date for payment.
Mail parts orders and payments by personal check to:
Hobby Services
3002 N. Apollo Drive, Suite 1
Champaign, IL 61822
Be certain to specify the order number exactly as listed in
the Replacement Parts List. Payment by credit card or
personal check only;no C.O.D.

6
IfadditionalassistanceisrequiredforanyreasoncontactProduct
Support by e-mail at pr[email protected], or
by telephone at [phone].
Replacement Parts List
Description How to Purchase
Missing pieces Contact Product Support
Instruction manual Contact Product Support
Full-size plans Not available
Contact your hobby supplier for the following parts:
GPMA3240 Wing
GPMA3241 Fuselage
GPMA3242 Vertical Stabilizer & Rudder
GPMA3243 Horizontal Stabilizer & Elevator
GPMA3244 Canopy/Hatch
GPMA3245 Wheel Pants
GPMA3246 Landing Gear
GPMA3247 Cowl
GPMA3248 Wing Tube
GPMA3249 Decal Sheet
COMMON ABBREVIATIONS
Stab = Horizontal Stabilizer
Fin = Vertical Fin
LE = Leading Edge
TE = Trailing Edge
LG = Landing Gear
Ply = Plywood
" = Inches
mm = Millimeters
SHCS = Socket Head Cap Screw
ESC = Electronic Speed Control
METRIC CONVERSIONS
1" = 25.4mm (conversion factor)
1/64" = .4mm
1/32" = .8mm
1/16" = 1.6mm
3/32" = 2.4mm
1/8" = 3.2mm
5/32" = 4.0mm
3/16" = 4.8mm
1/4" = 6.4mm
3/8" = 9.5mm
1/2" = 12.7mm
5/8" = 15.9mm
3/4" = 19.0mm
1" = 25.4mm
2" = 50.8mm
3" = 76.2mm
6" = 152.4mm
12" = 304.8mm
18" = 457.2mm
21" = 533.4mm
24" = 609.6mm
30" = 762.0mm
36" = 914.4mm

77
KIT INSPECTION
KIT INSPECTION
Before starting to build, take an inventory of this kit to make sure it is complete and inspect the parts to make sure they
are of acceptable quality.If any parts are missing or are not of acceptable quality, or if you need assistance with assembly,
contact Product Support. When reporting defective or missing parts, use the part names exactly as they are written in
the Kit Contents list.
Great Planes Product Support:
3002 N. Apollo Drive, Suite 1
Champaign, IL 61822
Telephone: [phone], ext. 5
Fax: [phone]
E-mail: [email protected]
1 Cowl
2 Fuselage
3 Spinner
4 Fuel Tank
5 Engine Mount
6 Main Landing Gear (L&R)
7 Nose Gear Wire
8 Nose Wheel Pant
9 Main Wheel Pants (L&R)
10 2-1/2" [64mm]Wheels (3)
11 Aluminum Wing Joiner Tube
12 Horizontal Stabilizer & Elevator
13 Vertical Fin & Rudder
14 Right Wing Panel w/Flap & Aileron
15 Left Wing Panel w/Flap & Aileron
KIT CONTENTS
KIT CONTENTS
KIT CONTENTS
46
8
14
13
7
1
312
510
11
15
2
9
9

8
PREPARATIONS
❏1.If you have not done so already, remove the major parts
of the kit from the box and inspect for damage. If any parts
are damaged or missing, contact Product Support at the
address or telephone number listed in the “Kit Inspection”
section on page 7.
❏2. Carefully remove the tape and separate all the
components. Use a covering iron with a covering sock on
medium/high heat to tighten the covering if necessary.
Apply pressure over sheeted areas to thoroughly bond the
covering to the wood.
BUILDTHEWING PANELS
Install the Aileron & Flap Servos & Pushrods
Before completing this section, confirm that the servos
that you will be using will properly fit between the servo
mounting block locations on the aileron and flap servo
hatch covers. Make adjustments as necessary for your
brand of servos. The block locations shown in this section
will fit a standard size Futaba brand servo.
❏ ❏ 1. Trim the covering from the servo arm cutouts in the
aileron and flap (if you will have operational flaps) servo hatch
covers.Useepoxytoglue the3/4" x3/4" x5/16" [19x 19x 8mm]
hardwood servo mounting blocks to the inside of the aileron
and flap hatch covers. Be sure that the blocks are aligned
over the rectangles with the grain direction perpendicular to
the covers. Allow the epoxy to cure undisturbed.
❏ ❏ 2.Cut three arms from a four-armed servo arm for the
aileron servo. Enlarge the outer hole of the remaining arm
with a 5/64" [2mm] drill bit.
❏ ❏ 3. Attach a 9" [229mm] servo extension to the aileron
servo and secure the connector using tape or heat shrink
tubing (not included). Center the servo with your radio
system and install the servo arm to the servo perpendicular
to the servo case as shown. Be sure to reinstall the servo
arm screw into the servo.
❏ ❏ 4.Position the servo against the underside of the aileron
servo hatch cover between the mounting blocks. Shim the
aileron servo away from the hatch cover approximately 3/64"
[1.2mm] to isolate it from vibration (a business card folded in
thirds works well for this). Drill 1/16" [1.6mm] holes through
the mounting tabs on the servo case into the blocks.Thread a
servo mounting screw (included with the servo) into each hole
and back it out.Apply a drop of thin CA to each hole to harden
the wood. When the CA has dried, install the servo onto the
hatch cover using the hardware supplied with the servo.
8

❏ ❏ 5.Use the string taped inside the aileron servo bay to
pull the servo lead through the wing ribs.
❏ ❏ 6. Thread a #2 x 3/8" [9.5mm] self-tapping screw into
each servo hatch mounting hole in the wing panel and back it
out. Apply a drop of thin CA to each hole to harden the wood.
Install the aileron hatch cover to the wing panel using four
#2 x 3/8" [9.5mm] self-tapping screws and four #2 flat washers.
❏ ❏ 7. Thread a nylon clevis 20 complete turns onto a
4" [102mm] pushrod. Slide a silicone clevis retainer onto the
clevis and connect the clevis to the outer hole of a control horn.
❏ ❏ 8.Position the control horn over the plywood plate in the
aileron (if you cannot see it, hold the aileron at a shallow angle
in good lighting or use a small pin to puncture the covering),
using the position of the servo arm as a guide.Align the holes
in the control horns directly over the aileron hinge line and
mark the location of the control horn mounting holes.
❏ ❏ 9. Drill 1/16" [1.6mm] holes at the marks you made
through the plywood plate. Do not drill all the way through
the aileron! Thread a #2 x 1/2" [13mm] self-tapping screw
through each hole and back it out. Apply a couple drops of
thin CA glue to each hole to harden the wood.When the glue
has dried, install the control horn onto the aileron using two
#2 x 1/2" [13mm] self-tapping screws.
9

10
❏ ❏ 10. Use tape or a small clamp to hold the aileron in
the neutral position. Make a mark on the pushrod where it
crosses the outer hole in the servo arm. Make a 90° bend
at the mark on the pushrod and cut off the excess pushrod
1/4" [6mm] beyond the bend.Attach the pushrod to the servo
arm using a nylon FasLink. Thread the clevis up or down
on the pushrod as necessary to center the aileron with the
servo arm centered.When satisfied, slide the silicone clevis
retainer to the end of the clevis to secure it.
Skip to step 13 if you are not installing operational flaps.
❏ ❏ 11.Install the flap servo onto the flap servo hatch cover
in the same manner (the flap servos do not require servo
extensions). Install the hatch cover to the wing panel using
four #2 x 3/8" [9.5mm] self-tapping screws and four #2 flat
washers. Be sure to harden the screw holes with thin CA.
❏ ❏ 12. Install a control horn onto the flap using two #2 x 3/8"
[9.5mm] screws. Make note that these screws are shorter
than the ones used for the aileron control horns. As you did
with the aileron, install a 4" [102mm] pushrod onto the flap.
Before connecting the pushrod to the flap servo, use your
radio system to operate the flap servo through the whole
range of motion. In order to achieve the recommended flap
deflection, use the end-point adjustment on your transmitter
to reduce the servo travel to approximately 50% of total (30
degrees, if applicable).
❏ ❏ 13.Route the servo lead(s) through the hole in the top
of the wing panel.
❏ 14. Repeat steps 1 to 13 for the other wing panel. When
installing the flap servo in the other wing panel (if applicable),
make note that both flap servos must be oriented in the same
direction (one flap servo arm will be facing the root rib and the
other flap servo arm will be facing the wing tip), in order for them
both to rotate the same direction when joined with aY-harness.

11
Fixed Flaps
If you are not installing operational flaps, follow these steps
to lock the flaps into the neutral position. If in the future you
choose to add operational flaps, simply cut the ABS strips
along the inside edge of each flap and install the flap servos
and linkage as described in previous steps.
❏ 1.Locate the two 3/4" x 1-1/2" [19 x 38mm] ABS flap strips.
❏ 2. Center the strips over the inside edge of each flap just
forward of the flap trailing edge. Use a felt-tip pen to trace
around the shape of the ABS flap strips onto the flaps and
wing panels.
❏ 3. Carefully remove the covering approximately 1/16"
[1.6mm] inside the lines you drew using a sharp hobby knife.
Take care not to cut into the wood when cutting the covering.
❏ 4. Wipe away the lines from the pen using a cloth
dampened with alcohol and glue the strips into position.
BUILDTHE FUSELAGE
Install theTail Surfaces
❏ 1. Place the horizontal stab onto the stab saddle in the
fuselage and align the three holes in the stab with the three
holes in the saddle. Align the holes in the vertical fin base
withtheholesinthestab.Presstheforwardendofthevertical
fin into the slot in the fuselage. Use three 6-32 x 1" [25mm]
SHCS and threadlocking compound to bolt the vertical fin
and horizontal stab to the fuselage.A strip of red covering is
provided to cover the screw holes if desired.
❏ 2. Temporarily insert a 36" [914mm] pushrod into the
elevator outer pushrod tube that exits the right side of
the fuselage. Use the position of the pushrod to mark the
location for the elevator control horn onto the underside of
the elevator.

12
❏ 3. Drill 3/32" [2.4mm] holes at your marks completely
through the elevator.Apply a couple drops of thin CA to each
hole to harden the surrounding wood. Install a control horn
and backplate onto the underside of the elevator using two
2-56 x 1/2" [13mm] machine screws.
❏ 4. Install a control horn onto the left side of the rudder in
the same manner.
Install theTail Servos & Pushrods
❏ 1.Cut two arms from a four-armed servo arm and enlarge
the outer hole of one remaining arm with a 5/64" [2mm] drill
bit and the second inner hole of the other remaining arm
with the same bit. Center the rudder servo with your radio
system and install the servo arm perpendicular to the servo
case as shown, with the outer drilled hole toward the center
of the fuselage.
❏ 2. Temporarily insert a 36" [914mm] pushrod into the
rudder outer pushrod tube. Use the pushrod to position the
rudder servo onto the servo tray in the fuselage as shown.
Align the outer hole of the inside servo arm with the pushrod.
Thread a servo mounting screw (included with the servo)
into each mounting hole in the servo and back it out. Apply
a couple drops of thin CA to each hole in the servo tray to
harden the surrounding wood. Mount the servo using the
hardware included with the servo.
❏ 3. Cut three arms from a four-armed servo arm and
enlarge the outer hole of the remaining arm with a 5/64"

13
[2mm] drill bit. Center the elevator servo with your radio
system and install the servo arm onto the elevator servo as
shown. Mount the elevator servo next to the rudder servo
with a gap of approximately 1/4" [6mm] between the tips of
the servo arms.Leave enough room for the throttle servo.
❏ 4. Thread a nylon clevis 20 complete turns onto a 36"
[914mm] pushrod. Slide a silicone clevis retainer onto the
clevis and connect the clevis to the third outer hole of the
rudder control horn. As you did with the aileron and flap
pushrods, use tape or a small clamp to hold the rudder in
the neutral position. Make a mark on the pushrod where it
crosses the outer hole in the servo arm. Make a 90° bend
at the mark on the pushrod and cut off the excess pushrod
1/4" [6mm] beyond the bend. Attach the pushrod to the servo
arm using a nylon FasLink. Thread the clevis up or down on
the pushrod as necessary to center the rudder with the servo
arm perpendicular to the servo case.When satisfied, slide the
silicone clevis retainer to the end of the clevis to secure it.
❏ 5. Install the elevator pushrod in the same manner. The
clevis on the elevator pushrod should attach to the outer hole
in the elevator control horn.
Glow Engine Installation
The Cherokee .40 ARF is designed to be flown with a .40 to
.46 two-stroke glow engine, .56 four-stroke glow engine, or a
brushless out-runner motor. If you plan to install a brushless
motor, skip this section as it only contains information
relevant to installing a glow engine.
Note:This section shows photos of a two-stroke engine
being installed.The procedure for installing a four-stroke
engine is the same. Be sure to maintain the correct drive
washer distance as detailed in this section.
❏ 1. The fuel tank can be assembled as a two line system
consisting of a vent (pressure) line to the muffler and a
carb line. Filling and emptying of the tank would need to be
done through the carb line, or an optional fuel fill valve (not
included). The tank can also be assembled as a three line
system having a vent line, carb line, and fill line. If installing
a fill line, puncture the top of the stopper above the sealed
off fuel tube hole. The fill and carb lines should extend out
1/2" [13mm] beyond the stopper and the vent line should
be bent upwards and left uncut. With the tubes installed in
the stopper, fit the stopper plates loosely in place with the
3 x 25mm Phillips screw to hold the assembly together.

14
❏ 2. Fit the stopper assembly into the tank with the vent
line pointing toward the top of the tank, but not touching.
The fuel tubing and clunks (fuel pickup) on the carb and fill
lines should almost reach the back of the tank but not touch.
The clunks must be able to move freely inside the tank when
assembled. Adjust the length of the fuel tubing accordingly.
When satisfied, tighten the 3 x 25mm screw in the stopper to
secure it in place (do not overtighten). Mark the side of the
tank that must face up when installed in the plane, and we
also suggest marking the tubes in the stopper.
❏ 3. Make two 12" [305mm] long hook and loop straps from
the included hook and loop material by overlapping the mating
ends of each side by approximately 2" [51mm]. Insert the
straps into the slots in the plywood fuel tank tray as shown.
❏ 4.Fit the fuel tank tray into the fuselage by inserting the tab
at the forward end of the tray into the slot in the firewall. Press
the tray down onto the receiving tabs in the fuselage former
and cross brace. Drill two 1/16" [1.6mm] holes through the
tray and into the hardwood mounting blocks. Secure the tray
in place using two #2 x 1/2" [13mm] screws and two #2 flat
washers, being sure to harden the screw holes with thin CA.
❏ 5.Cut a piece of 1/4" [6mm] foam rubber (not included) to
fit the fuel tank.Lay the foam rubber onto the fuel tank tray (it
can be glued into place). Insert the neck of the tank through
the hole in the firewall as far as it will go (being sure that the
right side of the tank is facing up). Use the hook and loop
straps to secure the tank in place.
❏ 6. Attach a 6" [152mm] piece of fuel tubing to each of the
tubes in the fuel tank stopper.
❏ 7. Using four 6-32 x 3/4" [19mm] SHCS, four #6 flat
washers,four#6lockwashers,andthreadlockingcompound,
attach the engine mount side-mounted to the firewall so that

15
the engine head will be on the right side. Leave the screws
slightly loose.Test fit your engine between the mount halves.
Slide the mount halves against the sides of the engine and
finish tightening the mount screws.
❏ 8. Position the front of the engine drive washer 4-15/16"
[126mm] from the front of the engine mounting box. (Note:
The dimension is the same for both four-stroke or two-
stroke engines.) Mark the location of the engine mount
holes onto the mount rails using a Dead Center Hole Locator.
Remove the engine from the mount and use a 6-32 tap and
drill set to create threads in the four mounting holes. Attach
theengine to the mount using four6-32 x 3/4" [19mm]SHCS,
four #6 flat washers, and four #6 lock washers.
❏ 9.Drill a 3/16" [4.8mm] hole in the firewall inline with throttle
arm in the carburetor using a long drill bit (if you do not have a
long drill bit, you may need to temporarily remove the engine).
Be sure you do not drill through the fuel tank! The hole in
the firewall must clear the exhaust port on the engine. Also
drill through the second former in the fuselage.
❏ 10.Cut a piece from the included outer pushrod tube long
enough to extend beyond the firewall and second former
approximately 1/4" [6mm]. Roughen the portion of the tube
that contacts the formers using 220-grit sandpaper.Glue the
tube into the holes with CA.
❏ 11.Cut three arms from a four-armed servo arm. Install a
brass screw-lock pushrod connector using a nylon retainer

16
into the third outer hole in the remaining servo arm, with a
4-40 set screw loosely threaded into the connector. Center
the throttle servo with your radio system and install the servo
arm onto the servo as shown. Use the hardware included
with the servo and install it next to the elevator servo.
❏ 12.Installanylonclevisandclevisretainer20completeturns
onto a 17-1/2" [445mm] pushrod. Insert the pushrod through
the forward end of the outer pushrod tube and through the
screw-lock pushrod connector on the throttle servo. Connect
the clevis to the throttle arm on the carburetor. If necessary,
bend the pushrod in order to clear the exhaust port. Make
the necessary adjustments so that the throttle servo properly
opens and closes the carburetor. Tighten the 4-40 set screw
against the pushrod. Cut off the excess pushrod 1/4" [6mm]
behind the screw-lock pushrod connector.
Brushless Motor Installation
If you have installed a glow engine, skip this section as it only
contains information relevant to installing a brushless motor.
Be sure to read and understand the instructions that come with
the ESC and motor before attempting to operate the system.
❏ 1. Attach the out-runner motor to the brushless motor
mount using the included 3 x 8mm machine screws and
threadlocking compound. If you haven’t done so yet, install
thepropadaptertothemotorcasewiththehardwareincluded
with the motor and threadlocking compound. Loosen the
screws that hold the two motor mount halves together and
set the distance from the back side of the mount to the front
of the prop adapter to be 4-15/16" [126mm]. Retighten the
screws using threadlocking compound.
❏ 2.Glue the two ESC mounting tray pieces together in the
orientation shown. Note that the mounting slots are slightly
offset toward the top side of the mount. Be sure that the

17
mounting halves are glued together in the direction shown.
Attach the mounting tray to the right side of the aluminum
motor mount using two 4-40 x 5/8" [16mm] machine screws,
two #4 flat washers and threadlocking compound (thread
the screws into unused holes in the aluminum mount). If you
are installing the recommended Great Planes ESC, glue the
three plywood washers onto the face of the mount. Rubber
band tabs are provided for other model ESCs.
❏ 3.If using the Great Planes ESC, install it to the mounting
tray using three #4 x 1/2" [13mm] self-tapping screws. Be
sure to harden the holes with thin CA. If installing another
model ESC, use rubber bands (not included) and self-
adhesive hook and loop material (not included) to secure
the ESC to the mounting tray.
❏ 4. Make two 12" [305mm] long hook and loop straps
from the included hook and loop material by overlapping the
mating ends of each side by approximately 2" [51mm].Insert
the straps into the slots in the plywood fuel tank tray as
shown.The fuel tank tray is also used as the battery tray for
a brushless installation.
❏ 5.Fit the fuel tank tray into the fuselage by inserting the tab
at the forward end of the tray into the slot in the firewall. Press
the tray down onto the receiving tabs in the fuselage former
and cross brace. Drill two 1/16" [1.6mm] holes through the
tray and into the hardwood mounting blocks. Secure the tray
in place using two #2 x 1/2" [13mm] screws and two #2 flat
washers, being sure to harden the screw holes with thin CA.
❏ 6. Drill a hole in the firewall for the battery lead from the
ESC and the receiver lead. Attach the motor mount to the
firewall using four 6-32 x 1/2" [13mm] SHCS, four #6 flat
washers,four #6 lockwashers,andthreadlockingcompound.
Connect the motor leads on the ESC to the motor. Be sure
that the leads will not interfere with the rotation of the motor.
❏ 7. Apply the hook side from self-adhesive hook and loop
material (not included) to the top of the fuel tank tray. A thin
coat of epoxy on the tray will improve the adhesion of the hook
material. Apply the mating loop material to the bottom of your

18
battery pack. Also use some self-adhesive hook and loop
material to join the 11.1V and 7.4V packs together.The straps
you made in step 4 are used to securely hold the battery
packs onto the tray. Test fit your packs onto the tray and cut
the straps to the desired length. Now would also be a good
time to confirm the correct rotation of the motor using the ESC
and radio system. If the motor rotates in the wrong direction,
unhook any two motor leads and swap their positions.
Assemble & Install the Landing Gear
❏ 1.While fitting the axle end of the main landing gear legs
into the main wheel pants, slide a 5/32" [4mm] wheel collar
onto each axle followed by a 2-1/2" [64mm] wheel and then
another 5/32" [4mm] wheel collar. Mark the location of the
threaded holes in the wheel collars onto the axles. Use a
file or rotary tool such as a Dremel to grind flat spots at the
marks on the axles.
❏ 2. Reinstall the wheel pants, wheel collars and wheels
onto the axles.Thread a 6-32 x 1/4" [6mm] SHCS into each
wheel collar with threadlocking compound and tighten the
screws against the flat spots on the axles. Be sure that the
wheels rotate freely on the axles.Oil the axles if necessary.
❏ 3.Place a landing gear strap over each gear leg and mark
the locations for the screw holes. Drill 3/32" [2.4mm] holes
at your marks, being sure not to drill into the wheels. Install
a strap onto each pant using two #4 x 3/8" [9.5mm] self-
tapping screws. Reinforce the holes with thin CA.
❏ 4. Fit the main landing gear legs into the slots in the
underside of the wing panels.Position two nylon landing gear
straps over each landing gear leg at a 45° angle as shown.
Mark the locations of the screw holes onto the wing and drill
holes at your marks using a 3/32" [2.4mm] drill bit.Secure the
landing gear legs to the wing panels using the nylon landing
gear straps and #4 x 1/2" [13mm] self-tapping screws.
❏ 5.Install the nosewheel pant and wheel ontothe nose gear
wire in the same manner as you did the main landing gear.

19
❏ 6. Fit a 5/32" [4mm] wheel collar into the nylon steering
arm, aligning the threaded hole in the collar with the hole
in the arm. Loosely thread a 6-32 x 1/4" [6mm] SHCS (with
threadlocking compound) through the hole in the arm and
into the collar. Install a brass screw-lock pushrod connector
using a nylon retainer into the outer hole on the steering arm.
Loosely thread a 4-40 x 1/8" [3mm] SHCS into the screw-
lock pushrod connector.
❏ 7. Fit the steering arm between the nylon steering block
halves. Insert the nose gear wire up through the steering
block and through the steering arm as shown. Tighten the
SHCS against the flat spot in the nose gear wire.
❏ 8. Align the bottom edge of the steering block with the
bottom edge of the hardwood mounting plate on the firewall.
Mark the locations of the four steering block mounting holes
onto the hardwood plate. Drill 3/32" [2.4mm] holes at the
marksyoumade.Mountthesteeringblockontothehardwood
plate using four #4 x 5/8" [16mm] self-tapping screws, being
sure to harden the holes with thin CA.
❏ 9. Cut off the threads from the remaining 12" [305mm]
pushrod, leaving all of the unthreaded portion of the
pushrod intact. Make a mark 3/16" [4.8mm] from one end
of the pushrod and make a 90° bend at the mark. Fit the
unbent end through the steering pushrod hole in the second
fuselageformerandout theholeinthefirewall.Fittheforward
pushrod end into the brass screw-lock pushrod connector on
the nylon steering arm. Insert the bent end of the pushrod
into the second inner hole in the unused side of the rudder
servo arm. Secure the pushrod onto the servo arm using a
nylon FasLink. With the rudder servo arm perpendicular to
the servo case, rotate the nose gear wire so that the nose
wheel is pointing straight. Tighten the SHCS in the brass
screw-lock pushrod connector against the pushrod.

20
❏ 10. With the nose gear in place, the muffler can now be
installed onto the engine (if applicable). Either the stock
muffler can be used or a Pitts style muffler. If using the stock
muffler included with the engine, a muffler extension will be
required. If installing the O.S. Max #873 muffler extension
(OSMG2578), the bottom right corner of the fuselage will
need to be carved away in order to accommodate the
muffler body. The firewall has dashed markings in this area
indicating the location of the pre-installed balsa block behind
the firewall. A piece of white MonoKote is included with the
Cherokee .40 ARF for covering up the area that was carved
away.No modification needs to bedone to the fuselage when
using a Pitts style muffler. However, we did cut the exhaust
outlets slightly shorter for this installation.
❏ 11. If you haven’t done so already, cut the fuel line and
vent line (to muffler) to the correct length and connect them
to the engine.The fill line should be left uncut and it can hang
free from the bottom of the plane.A fuel line plug is provided
for the fill line.
FINISHTHE MODEL
Install the Receiver
❏ 1. Make straps from the included hook and loop material
to fit your receiver and receiver pack. Cut pieces of foam
rubber (not included) to fit your receiver and receiver pack
and strap them to the radio tray as shown.
❏ 2. Connect the servos to the receiver, being sure that the
leads will not interfere with the tail pushrods. Depending on
the ESC being used (if applicable), you may need a servo
extension to reach the receiver. If you plan to connect the
flap and aileron servos to the receiver using Y-harnesses,
connect the harnesses to the receiver at this time.
❏ 3.Install your receiver switch and charge jack onto the sides
of the fuselage. Confirm that the location of your switch and
charge jack will not interfere with the wing bolts when installed.