GREAT PLANES Easy Sport 40 User manual

Assembly manual for the Easy Sport 40 and 60
WARRANTY
Great PlanesModelManufacturingCoguarantees this kitto befree from defects inboth material and
workmanship at the date of purchase This warrantydoes not cover any component parts damaged byuse 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 warranty without notice
Inthat Great Planes has nocontrolover the finalassembly or material used forfinal assembly, noliability
shallbeassumed nor accepted forany damage resulting from the use bythe user of the finaluser-assembled
product Bythe actof using the user-assembled product, the user accepts all resulting liability
Ifthe buyers are not prepared to accept the liability associated with the useof this product, they
are advised to return this kit immediately innewand unusedcondition to the place ofpurchase.
READTHROUGHTHISINSTRUCTIONBOOK
FIRST.ITCONTAINS IMPORTANT INSTRUCTIONS
AND WARNINGS CONCERNING THE ASSEMBLY
AND USEOF THIS MODEL.
ESP46P03 6/96V 1 0
PO Box 788UrbanaIllinois61801 (217)3988970
EntireContents © Copyright1996

Introduction ...............................................................3
Precautions...............................................................3
Abbreviations ............................................................4
Types of wood...........................................................4
Metric conversion chart.............................................4
Decisions you must make......................................4
Engine selection ....................................................4
Landing gear configuration ....................................4
Die-cut patterns.....................................................5,6
Required items..........................................................7
Tools andsupplies ....................................................7
Preparing the work surface.......................................7
Get ready to build......................................................8
Tailfeathers.............................................................8
Build the rudder .....................................................8
Buildthe fin............................................................9
Build the stabilizer..................................................9
Buildthe elevators ...............................................10
Join the elevators.................................................10
Installthe hinges..................................................10
Wing assembly......................................................12
Prepare wing parts...............................................12
Spars...................................................................12
Ribs......................................................................12
Leading andtrailing edges...................................13
Leading edge joiner .............................................13
Buildthe wing panels...........................................13
Join the wing panels ............................................15
Install the center ribs and sheeting......................17
Installthe wing tips ..............................................21
Installthe ailerons................................................21
Installthe wing boltplate.....................................22
Fuselageassembly...............................................23
Fuselage sides.....................................................23
Firewall assembly ................................................24
Former preparation..............................................26
Assemble the fuselage ........................................26
Install landinggear mounts..................................28
Install the firewall .................................................29
Install the landing gear blocks .............................30
Installthe pushrodguidetubes............................32
Finish the fuselage...............................................33
Finalassembly.....................................................35
Cut center fairing fromfuselage...........................35
Mount wing to fuselage........................................36
Engine installation................................................40
Fuelproof the fuselage.........................................40
Installhorizontalstab...........................................41
Installvertical fin..................................................41
Mount landing gear..............................................42
Finalfitof the engine ...........................................44
Installradio and pushrods....................................44
Finishing................................................................46
Additional fuelproofing .........................................46
Balance the airplane laterally...............................46
Remove the engine and radio..............................47
Final sanding .......................................................47
Covering ..............................................................47
Recommended covering sequence.....................47
Applying trim anddecals......................................47
Glue the hinges....................................................48
Install the pilot......................................................48
Install canopy.......................................................49
Wing seating........................................................49
Reinstallengine&radio.......................................50
Install wheels.......................................................50
Balance your model .............................................50
Finalhookups andchecks ...................................51
Preflight................................................................51
Balance the propeller...........................................51
Finda safe place to fly.........................................51
Ground check the model......................................52
Range check the radio.........................................52
Engine safety precautions ...................................52
AMA safety code ...................................................53
General................................................................53
Radiocontrol........................................................53
Flying .....................................................................53
Takeoff.................................................................53
Flying...................................................................53
Landing................................................................54
Two-viewdrawing..................................BackCover
2

YourEasySportisnota toy,but rathera
sophisticated, working model that functionsverymuch
likeanactual airplane.
Becauseofitsrealisticperformance,theEasy
Sport, if not assembled and operated correctly,could
possiblycauseinjuryto yourselfor spectatorsand
damage property
Tomake your R/C modeling experience totally
enjoyable, we recommend that you get experienced,
knowledgeable help with assembly and during your
first flights.You'll learn fasterand avoid risking your
modelbefore you'retrulyready to solo Your local hobby
shop has informationabout flyingclubs in yourarea
whose membership includes qualified instructors
You canalsocontactthenationalAcademyof
Model Aeronautics (AMA),which has more than 2,300
chartered clubs across the country Through any one of
them,instructortrainingprogramsandinsured
newcomer training are available
Contact the AMA atthe address ortoll-free phone
number below.
Academy ofModelAeronautics
5151 East Memorial Drive
Muncie, IN47302-9252
Tel:[phone]
Fax:[phone]
The Easy Sport is not a beginner'sairplane'Itis
relativelyfast,highly maneuverable,and lacks the self
recovery characteristics of a good basic trainer such as
the Great Planes PT-40 Mkll Ifyou have already learned
the basicsof R/C flyingand can safelyhandle a basic
trainer,the Easy Sport isan excellent choice to sharpen
your skills and learn more advanced maneuvers
We thinkyouwillagreethattheGreatPlanes
Easy Sport isthe highest quality, best flyingmodel of its
type on the market today'
Pleaseinspect all parts carefully before starting
to build!Ifany parts are missing, broken or defective,
or ifyou have any questions about building or flying
this model,please call usat [phone] and we'll
beglad to help.Ifyou are calling forreplacement
parts, please look upthe part numbers and the kit
identificationnumber (stamped on the end of the
carton) and have them ready when calling.
Remember:Take your time andfollow directions to
endupwith a well-builtmodelthatisstraightandtrue.
Thank you for choosing the Great Planes Easy Sport
as yournew projectNow thatyouhave masteredthe
basics of flightwithyourprimarytrainer,youare now
ready to advance to the next higher level - a level that will
open the doors to aerobatics With the experience you ve
acquired withyourtraineralong withthe Great Planes
Easy Sport,youwillbe abletoexperimentwith,and
master, the maneuversthatyourclubprosperform
The Easy Sport, withits shoulder mounted wing,
rugged constructionand heavy-dutylanding gear, will
allow youto practice and perfectany maneuver you
desire But don't let itsaerobatic qualities put you off
The Easy Sport isalso an extremelydocile flierThanks
to its thick semi-symmetrical airfoil, generous moments
and light wing loading, you'll beable to "grease her in"
every time
Ifyou'vemastered your trainer and are ready to
progresstoadvancedflightmaneuverstheGreat
PlanesEasy Sportis justtheticketforeasy-flying,
smooth aerobatics Welcome to the world of sport flying
1.You mustassembletheplane accordingtothe
instructionsDonot alter or modify the model, as doing
so may result inan unsafe or unflyable model Ina few
cases the instructionsmay differslightly fromthe photos.
Inthoseinstancesyoushouldassumethewritten
instructions are correct
2.You must take time to build straight, true and strong
3You must properly install allR/C components and
other items so that the model operates properly on the
ground and inthe air.
4You must test the operation of the model before the
firstandeachsuccessiveflighttoinsurethatall
equipment isoperating, and you must make certain that
the model hasremained structurally sound
3

Both the Easy Sport 40 and 60 are built from this
manual. Nearly all the parts inthe Easy Sport series
are identical, so most of the differences are only inthe
size andthicknesses of the pieces - you can't even
tellfrommostofthephotosWhenimportant
differences do arise between the 40 and 60, they are
clearly indicated so you'll have allthe information you
needto buildyour model.
Commonly used abbreviations
deg = Degrees
Elev = Elevator
Fuse= Fuselage
LE= LeadingEdge
Ply= Plywood
Rt= Right
Stab = Stabilizer
TE = Trailing Edge
(rear)
"= Inches
(front)
LG= LandingGear
Lt= Left
BalsaBasswood Plywood
The recommended engine size range isasfollows:
Easy Sport 40 Easy Sport 60
40 to 50 cu in2-stroke .60to 90 cu in2-stroke
.60to .80cu.in.4-stroke .70to 1.20cu.in4-stroke
TheEasySport40willflywellwithanyofthe
recommendedenginesizesFor "HotDogging"and
speedy performance we suggest either an 0 S 46FX or
aSuperTigre"GS-45, both 2-strokeengines AnO.S.
FS-70 Surpass is a good choice for those who prefer
4-stroke engines
Forthe Easy Sport 60,an O.S.61SFor a SuperTigre
S-61K will have you burning holes inthe sky with power
to spare If a 4-strokeengine is what you desire, the
O.S.FS-91 isthe perfect choice
The Great Planes Easy Sport can be set upwith
tricyclegear (nosewheel)or builttobe a taildragger
Many pilots prefertaildraggers as theyare more sporty
looking and offerless drag than thetraditionallanding
gear configurationBut theycan present minor ground
handlingproblemsTricyclegear,on theotherhand,
provides stable tracking during takeoff and landing, butis
heavier and creates more drag than a tail wheel.
If youchoosetobuildyourEasySport40 as a
taildragger,youwillneed topurchasea wiretailgear
assembly (GPMQ1900), a 1"tail wheel (GPMQ4241) and
two 3/32" wheel collars (GPMQ4302) Forthe Easy Sport
60 you willneed to purchase a wiretail gear assembly
(GPMQ1900),a 1-1/2"tailwheel(GPMQ4243)and two
3/32" wheel collars (GPMQ4302).
Metric Conversion Chart
1/64"
1/32"
1/16"
3/32"
1/8"
5/32"
.4mm
.8mm
1.6 mm
2.4 mm
3.2mm
4.0mm
3/16"
1/4"
3/8"
1/2"
5/8"
3/4"
Inches x 25.4
= 4.8 mm
= 6.4 mm
= 9.5 mm
=12.7mm
=15.9mm
=19.0mm
mm (conversion factor)
1"
2"
3"
6"
12"
18"
25.4 mm
50.8 mm
76.2 mm
152.4 mm
304.8 mm
457.2mm
21"
24"
30"
36"
533.4mm
609.6mm
762.0mm
914.4 mm
4

5
DIE-CUTDRAWINGS
UseThisDiagram ToLocate Die-CutParts ForThe Easy Sport 40.

6
DIE-CUTDRAWINGS
UseThis Diagram ToLocate Die-CutParts ForThe Easy Sport60.

DFour-channelRadio With 4 Servos
DEngine(see page 4)
DGlow Plug(see engine instructions)
DPropeller(see engine instructions forsizes)
D1/4"Thick Foam Rubber (HCAQ1000)
D12"Silicone FuelTubing(GPMQ4131)
Accessories Required to Complete YourEasySport40
D2-1/2"Spinner(GPMQ4520)
D10oz.FuelTank (GPMQ4104)
D(3)2-1/2" Wheels (GPMQ4223)
DWheel Collars (2ea ) 5/32" (GPMQ4306)
(4ea)3/16"(GPMQ4308)
D(2rolls)Covering Top Flite MonoKote
DOptional: Wire TailGear Assembly (GPMQ1900)
D1"TailWheel (GPMQ4241)
D(2)3/32" Wheel Collar (GPMQ4302)
DPilot1-1/2"Scale
DGreat PlanesEasySportTrim Graphics
(GPMQ0405)
Accessories Requiredto CompleteYour EasySport60
D2-3/4" Spinner(GPMQ4525)
D14oz FuelTank(GPMQ4106)
D(3)3"Wheels (GPMQ4224)
D3/16" Wheel Collars (6 ea ) (GPMQ4308)
D(3rolls)Covering Top Flite MonoKote recommended
DOptional: Wire TailGearAssembly (GPMQ1900)
D1-1/2"TailWheel (GPMQ4243)
D(2)3/32" Wheel Collar (GPMQ4302)
DPilot1-1/2"Scale
We recommendGreatPlanesProCA and Epoxy
adhesives
D2oz. CA (Thin) (GPMR6003)
D2oz. CA+ (Medium) (GPMR6009)
D1oz.CA- (Thick) (GPMR6014)
D6-Minute Epoxy (GPMR6045)
D30-Minute Epoxy (GPMR6047)
DHandorElectric Drill
D 5/32"
D3/16"
D 1/4"
D15/64"
D19/64"
DrillBits.
D 1/16"
D 5/64"
D1/8"
D 7/64"
D 9/64"
DString
DBuildingSquare: (XACR7726)
DBuildingTriangle: (XACR7725)
DStraightedge With Scale
DMasking Tape
DWaxed Paperor Plastic Kitchen Wrap
DHobbyLite" Balsa Filler(HCAR3401)
DPetroleum Jelly
DEasy-Touch" Bar Sander andSandpapersee the
following Expert Tip
DDremelMultiPro'"or similar (Optional)
D1/8"x 2"Brass Tube(Optional)
DSealingIron(TOPR2100)
DHeatGun (TOPR2000)
DHobbySaw (XACR1435)
D#1Hobby Knife (XACR4305)
D#11 Blades(HCAR0311, 100qty.)
DRazor Plane(MASR1510)
DPliers
DScrewdrivers (PhillipsandFlatBlade)
DT-Pins:short (HCAR5100) and long (HCAR5200)
Tobuild the Easy Sport, you willneed a 15" x 48"
(minimum size) flat surface Because your model willbe
nostraighterthan thissurface,itis criticalthatitis
truly flat
Thesurfaceofthe workareashouldbe ofa
material that you can push pins into, such as a piece of
7

ceiling tile Before beginning to build,use a straight edge
to check foreand aft,side toside and diagonally for
warps Shim your board untilitisexactly flat.
D1 Unroll the plansheet Reroll the planinside out to
make itlie flat.
D2 RemoveallpartsfromtheboxAsyoudo,
determine the name of each part by comparing itwith
the plans and the parts list included with this kit Using a
felttip or ball point pen, writethe part name or size on
eachpiece toavoidconfusionlaterUse thedie-cut
patterns shown on pages 5 and 6 to identify the die-cut
parts and mark them before removing them fromthe
sheet Save all scraps Ifany of the die-cutparts are
difficulttopunch out,do not forcethem'Instead, cut
around the parts with a hobby knife After punching out
thedie-cut parts use yourbar sander to lightly sand
theedges to remove any die-cutting irregularities
D3 Asyou identify and mark the parts, separate them
into groups,such as fuse (fuselage), wing, fin, stab
(stabilizer) andhardware.
D1 Tape thefuselage plan down toyourflatwork
surface Tape a piece of waxed paperover the finand
rudder portion of the plan
D2 Using a razor saw, cut pieces of 5/16" x 3/4" and
5/16"x 1/2" balsa (fromthe30" sticks)tomake the
rudder framework. Working right on the plan, pin these
parts inplaceandglue them together using thin CA glue
D3 From the 5/16" x 1/2" x 30" sticks, cut braces to fit
between the rudder frameworkand glue them inplace
Note: Itis not necessarytoget thesebracesin the
exact position shown on the plan Ifyou re building the
Easy Sport 40, cut a 1"piece fromthe 5/16" x 3/4"
balsa stick Ifyou arebuilding the Easy Sport 60, cut a
1-1/4" piece fromthe 5/16" x 3/4" balsa stick From this
small piece cut the triangular gusset forthe frontbottom
corner of the rudder.
D4 Removetherudderfromyourbuilding surface
Examine and addthick CA glue to any open jointsThen
use your sanding block withmedium (150-grit)sandpaper
to sand both sides of the rudder framework smooth
D5 Carefullydraw a centerline allaround the edges
oftherudder(thiswillhelp tomaintainsymmetry
when sanding).
8

D6 Usinga sandingblockandmedium(150-grit)
sandpaper, sand the leading edge toa "V-shape" as
shown on the planSand the bottom of the rudder to the
shape as shown on the plans Sand the trailing edges,
bottom edges and top to a rounded shape
At this point, you should have given some thought to the
landing gear configuration you would like to use Ifyou
have decided to build your Easy Sport asa taildragger,
follow the simple instructionsoutlined in the box below.
Onthe other hand, if you would prefer your Easy Sport
witha conventionaltricyclelanding gear, skip the box
and continue construction at Build The Fin.
D1 Inthe same manner as the rudder, build the fin
using the 5/16" x 3/4" and5/16" x 1/2" balsa sticks
D2 Carefullydraw a centerline on the leading and
trailing edges of the fin.
D3 Sand (only) the leading edge to a round shape.
NOTE: The trailing edge and bottom edge must not be
rounded or V-shaped Instead, justsand theseedges
flat andsquare Donot sand the top edge at this time.
D1 Tape waxedpaper over the separate stabilizer
drawingon thefuseplan Pin theshaped balsa stab
joinerin place directlyover the plans Then, inthe same
manner as the rudder, cut balsa pieces and build the
stab framework.
D1 Checktheplans and mark thelocationofthe
optional tailgear on the rudder Drill a 7/64" hole inthe
rudder (the hole isdrilled slightly oversize to allow for
positioning,and tocreatea hardepoxy"sleeve"
around the wire) Then groove the rudder leading edge
to accept the tailgear wireHINT:Using a hobby knife,
sharpen the inside of one end of a 1/8" diameter brass
tube, and use itto cut the grooveinthe leading edge
of the rudder.
D2 Shape the stab tips to the shape as shown on
the plan.
D3 Carefully draw a centerline all around the edges of
the stabilizer
D4 Sand the leading edge and tip to a round shape.
NOTE: Thetrailingedgemustnot be roundedor
V-shaped Instead, justsand thisedge flat and square.
9

D1 Inthe same manner as the rudder, build each
elevatorusingthe5/16"x 3/4"and 5/16"x 1/2"
balsa sticks
D2.Shape the elevator tips to the shape asshown on
the plan.
D3.Carefully draw a centerline allaround the edges
of the elevators.
D4.Sand the leading edge to a "V-shape Sand the
trailing edge and the outside edge of the tip to a round
shapeasshown on the plans.
D6 Trial fitthe joinerwireinto the elevatorsThen
glueitin using6-minuteor 30-mmuteepoxyWhen
gluing,laytheelevatorson a flatsurface,withthe
leading edges along a straightedgetoinsureperfect
alignment Cover the top of the joined elevators with a
sheet of waxed paper Then laya flat,heavy object on
top A telephone book works wellThis will insure a true,
flat elevator assembly when the epoxy cures
(Do notglue)
D1 Temporarily pin the elevators and stab over their
respective drawings on the plan
D2. Laythe 1/8"wire elevator joiner inplace on the
elevators andmarkitsoutline usinga fine pointfelt-tip pen
D1.Cut18hinges (3/4" x 1")fromthe 2"x 9"CA hinge
stripTrim the cornersat a 45 degree angle to make
insertion easier.
D2 Laythe rudder and elevators on the plan and mark
the hingelocations. Place the rudder against the finTE
and transferthe marks to thefinPlace theelevators
against the stab TE andtransferthe marks to the stab.
D3 Accurately drillholes inthe elevators for the 1/8"
wire joinerBegin by drilling a 1/16" or 5/64" pilot hole
Then drill the finalhole to a depth of 7/8" with a 9/64"
drill bit(The hole isdrilled slightly oversize to allow for
positioning, andto create a hardepoxy "sleeve" around
the wire)
D4 Usethe sharpened 1/8"diameter brass tube or a
drillbit tocuta grooveintheleadingedge ofthe
elevators to accept the joiner wire.
CAUTION:Youmustuse extremecarewhen
cutting hinge slots with a hobby knife, to avoid
cutting yourself! Ifthe balsa part breaks while you
are pushing on the knife, the blade could go into
your handbefore you know it!A good precaution
isto wear leather gloveswhileperformingthe
followingsteps,and alwayscut awayfrom
yourself.
D5 Roughen the joiner wirewith coarse sandpaper,
then clean the wire thoroughly with alcohol to remove
any oily residue.
D3.Cutthe hinge slots on the accurate centerlines
which you previously drew, using a hobby knife or a
slotting forkand slotting hook (The recommended hinge
slotting technique isexplained on the next page.)
10

power or hand drill Drilling the hole will twist some of the
wood fibers into the slot, making itdifficultto insert the
hinge,so you should reinsert the knife blade, working it
backandforth a fewtimes to clean out the slot.
INSTALLINGCA HINGES
The hingematerial suppliedinthis kitconsists of a 3-layer
lamination of mylar andpolyester Itisspecially madefor
the purpose of hinging model airplane control surfaces
Properly installed, this typeof hinge provides the best
combination of strength, durability andease of installation
We trust even our best show models to these hinges, but
itisessential to installthem correctly Please read the
following instructions and followthem carefully to obtain
thebest resultsTheseinstructionsmay be used to
effectively install any of the various brandsof CA hinges.
The most common mistakemade by modelerswhen
installing this typeof hinge is not applying a sufficient
amount of glue to fullysecure the hinge over its entire
surface area, or,the hingeslots are very tight,restricting
the flow of CA to the back of the hinges This results in
hingesthat are only "tack glued" approximately 1/8"to 1/4"
into the hinge slots. The followingtechnique has been
developed to helpensurethorough andsecure gluing.
Note: When hinging the rudder and elevator which use
torque rods, use a toothpick to forceepoxy down the hole
drilled forthe torque rod Inthe case of the rudder, be
sure notto letglue getintothe bearing tube.
CInsertthe hinges andinstall the control surface Verify
the left-right positioning of the control surface and close
upthe hingegapto 1/32" or less Itisbest to leave a very
slight hinge gap, rather than closingituptight,to help
prevent the CA fromwicking along the hinge lineMake
sure the control surface will deflect to the recommended
throws without binding Ifyou have cut your hinge slots
too deep, the hinges may slideintoo far, leaving only a
small portion of the hinge inthe control surface Toavoid
this, you may insert a small pin through the center of
each hinge before installing This pinwill keep the hinge
centered while installing the control surface Remove the
pins before proceeding
A. Cut the hingeslot using a #11bladeina standard #1
knife handle The CA hinges provided have a thickness
that fitsthis type of slot very well Trial fitthe hinge into the
slot Ifthe hinge does not slide ineasily, work the knife
blade back and forthinthe slot a fewtimes to provide
more clearance (itisreally the back edge of the blade
that does the work here inwidening the slot)
B.Drilla 3/32" hole, 1/2"deep, Inthe center ofthe
hingeslot. Ifyou use a Dremel MultiPro for this task, it
will result ina cleaner hole than ifyou usea slower speed
ASSEMBLE THEN APPLY 6 DROPS
OF THIN CA TO CENTER
OFHINGE, ON BOTH SIDES
D4 Apply 6 drops of thin CA adhesive to both sidesof
each hingeon the elevators and rudder only - notthe
ailerons yet. Allow a fewseconds between drops forihe
CA to wick into the slot Note that the small "tunnels you
created bydrilling the 3/32" holes allow the CA to freely
travel into the entire surface of the hinge, producing an
extremely secure bond
11

D4 Insertthe hingesintothe slots andtrialfit the rudder
andelevators inplace on the finand stab Donotglue
the hingesuntilafter you have covered the model.
Before assembling the wing there are a fewpreliminary
assemblies that must bemade.
TWO WARPED SPARS INSTALLED
THISWAY WILL RESULT INA
STRAIGHT WING
TWO WARPEDSPARS INSTALLED
THISWAY WILLRESULTINA
WARPEDWING
D1 Before using the basswood spars examine them
carefully forpossible imperfections Look forknots soft
spots,diagonalgrainand any otherimperfectionsIf
possible, position each spar so the imperfections (if any)
are on the outer half of the wing panel (towards the tip)
wheretheywillbe less affectedby high stressIfthe
spars are warped slightly, try to "balance them out" by
installing the warped spars inopposite directions(see
sketch) NOTICE: Ifyou feelthatany of the wing parts
are unusable due to severe warps or other defects,give
usa call and we'll replace the parts.
D1 Carefully punch out allthe die-cut balsa wing ribs
Sand theedgesslightlytoremoveanydiecutting
irregularities and arrange them into stacks of the same
kind of ribs.
DD 2 Locate the two #3 and #4 ribs Center one #3
ribonone#4ribusingthelighteningholesas a
referenceTherewillbe a 3/32"offsetbetweenthe
edges of rib #3 and #4 when properly aligned
NOTE: The embossed "T"on both ribs should face the
same direction While holding inthe above position, glue
these twopieces together with thin CA NOTE: The ribs
are not symmetrical, so besure to make a rightand left
assembly
D3 Locate the two 1A ribsections Take care to align
these ribs using the notches asreferencesGlue the 1A
ribs together with thin CA forthe Easy Sport 40 Glue
the1A ribstogetherwith6-minute epoxyforthe
Easy Sport 60
D2 Glue a 1/4" x 3/8" x 9-78" (1/4"x 1/2" x 10" forthe
Easy Sport 60) basswood spar doubler to a 1/4" x 3/8"
x30" (1/4" x 1/2" x 32" forthe Easy Sport 60) basswood
mainspar with medium CA asshown Sand the edges
of the spars to remove any excessglue and to make the
edges uniformMake four spar assemblies Refer to the
cross-section fororientation
D4 Locate and align the two1C ribs as described
above andglue them together with thin CA
12

DD The shaped and notched wing leading edges (LE)
and trailing edges (TE) are fastened together by thin
strips of balsa. Separate them by cutting with a hobby
knife, asshown inthe sketch.
DD 2.Layone of the 3/32" x 1-3/4"x 30"(3/32" x 2"x
32" forthe Easy Sport 60) balsa TE sheets on the wing
plan, lining itupwith the outside edge of the tip rib. Pin
inplace. Any excess balsa will extend beyond the wing
centerline.
DD 3.Place a basswood main spar on the plan,
liningupthe outboard end of the spar doubler withthe
plan. The main spar will extend beyond the root and tip.
This will betrimmed off later. Donot pin this spar down
to the plan - justuse pieces of masking tape on the
ends, to prevent itfrommoving.
DLocate both die-cut1/8" ply leadingedge joiners
(ifnecessary, referto the die-cut patternson page 6).
Drill a 1/8" hole at the punch mark. Then, follow through
again with a 1/4" drill.
READTHIS BEFORE YOUBEGIN BUILDING THE
WING PANELS: Itis veryimportantthatyoubuild a
straight wing with no warps or twistsor you will get some
flyingcharacteristicsyou didn't expect'Beverycareful
when you align theribs, spars, leading edges, trailing
edges and sheeting inthe followingsteps. Allof these
parts should beintheir correct positions before you glue
them inplace. Hold or pinthe parts in place, then glue.
The followinginstructionswillguide youthroughthe
building of a straight, warp-freewing.
NOTE: You will build the right wing panel first(steps 1
through17).Then followsteps 2 through 16again to
buildthe leftwing panel.
VERYIMPORTANT: The ribs are stamped with a "T"
which always denotes the top of therib.
D1.Tape the wing plan to your flatbuilding surfaceso
that the Right Wing Panelisfacing you.Tape a sheet
of waxedpaper or plastic kitchen wrap over the right
wing panel drawing.
DD 4.Place the #5, #6 and #7 ribs (#4, #5 and #6
ribsfortheEasySport60)ontothemainspar.
Remember: The stamped "T"denotes the top of the rib.
DD 5.Now, place one of theshaped and notched
balsa TE'S on the TE sheet (the end withthe closely
spaced notches must beat the wing root).Note: The TE
isnot symmetrical - referto the cross-sectionforproper
orientation.WorktheTE ontotheback oftheribs
starting at rib #7 and working towards rib #5 (start atrib
#6 and work towardrib # 4 on the Easy Sport 60).The
TE sheetmay overhangtheshaped and notched TE
slightly. This isnot a major concern because any excess
will besanded off later. Make sure that ribs are inserted
all the wayinto theTE notchesand touchingtheTE
sheet. Glue the shaped TE and ribs to the TE sheet with
thin CA.
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NOTE:Donot betoo concerned ifthe ribs do not lineup
exactly with the plan. Sometimes the humidity will cause
theplanto expand or contract. Just remember to line up
the leading edge, trailing edge and ribs with the outside
edge of rib #7 (rib#6 on the Easy Sport 60). Let the
pre-cut notches take care of the spacing.
DD 6.Place the shaped and notched LE on the frontof
the ribs.Onceagain,theend withthecloselyspaced
notches must facethe wing root. Center the LEvertically
on the ribs, so the top and bottom edges of the ribs are
flush withthe shaped LE.When certain that the shaped LE
iscentered andinposition,glueitto the ribswith thin CA.
DD 8.Insert the uppermain spar and a 3/16" x 3/16" x
30"balsa frontspar (3/16" x 3/16" x 32" basswood
front spar on theEasy Sport 60) into the notches inthe
tops of the ribs. The upper main spar should bealigned
directlyover the lower main spar. The upper frontspar
should be flushwith theouteredge of rib #7 (rib #6 on
theEasy Sport 60). Donot trimoff any excess material
fromthe main or frontspars yet.
DD 9.Make sure allribsare vertical (90 degrees to
the work surface), that the spars are lined upand that all
parts are properly aligned. Glue the ribs to the upper,
lower and front spars with thin CA.
DD 10. With medium CA, glue the pre-cut 1/16" x
1-3/4" x 3-3/8" (3/32" x 2" x 3" on the Easy Sport 60)
balsa shear webs to the back of the main spars fromrib
#5 thru#7 (rib#4thru#6 on theEasy Sport60) as
shown on the plans. Itisnotnecessary forthe webs to
beglued to the ribs.
DD 7.Put ribs #2, #3 and #4 inplace on the main
spar.Note that the spar notches are cut extrawide to
allow forthe wing joiners. Refer to the sketch and note
that itis most important to centerthe rib foreand aft,
providing equal space infrontof and behind the spar.
Insert the ribs into their notches inthe shaped LEand
TE. Center the ribs vertically on the LE(rib #2 will have
a3/32"spaceontopandbottomwhenproperly
centered).Glue both ribs to the shaped LE,TE sheet
and shaped TE with thin CA.
DD 11.Position one of the TE sheetson top of the
shaped TE so one end iseven with the jointbetween
ribs #3-4 and glue itin place. NOTE: Toget a good glue
jointyou should properly position the TE sheeting and
apply thinCA where itjoins each rib. Second, apply thin
CA along the rear edge wherethe sheeting meets the
small edge of the shaped TE. Finally, unpin and remove
the wing from the building surface. Stand the wing upso
the LEisupand the TE is down and drip a couple of
drops of thin CA into the jointwhere the sheeting meets
the wide edge of the tapered TE.
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DD 12. Turn the wing panel upside down and install a
front spar on the bottom of the wing. Glueinplacewith
thinCA.
NOTE: Make surethatthe DG is facingtheproper
direction.Remove the wingfromthebuilding surface
andusinga razorsaw,carefullycutoffallexcess
sheeting, spars, LEand TE even with the lines you just
drew. Now, sand the ends of the parts you justtrimmed
until they are smooth and flushwith the lines.
DD 13.Turn the wing right side upand glue the #8 ribs
inplace with medium CA. Use the planasa guidefor
positioning the ribs.
D17. Turn the wingplan aroundso the Left Wing
Panelisfacing you. Cover itwith waxed paper and build
the leftwingpanel inthesame manner as the right
panel, following steps 2-16.
DD 14.Now, go over the entire wing panel making
sure all jointsare securely glued. Add thin and/or thick
CA glue wherenecessary. Make sure that you double
gluethe shear webs with mediumCA.
DD 15.Using a razor saw, carefully cut off allexcess
sheeting, spars, LEand TE even with the outboard edge
of rib #7 (rib #6 on the Easy Sport 60). Now, sand the
ends flush with the face of the rib.
D1.Locate the two 1/16" (1/8"on the Easy Sport 60)
birch ply wing joiners. Before youremove them from
the die-cut sheet, draw a lineconnecting the two punch
marks using a pencil and straightedge. Besure to mark
both sides.
D2.Startingwiththe right wing panel, test fitthe wing
joinersto the frontand rear of the main spar. The wing
joinersmust slide farenough so that the pencil marks
lineupwith the ends of the spar.
DD 16.Temporarily pinthe wing half back over the plan.
On the Easy Sport 40, place the dihedral gauge (DG) on
the centerlineas shownand mark the LE, frontspars,
main spars, TE sheeting and TE. Onthe Easy Sport 60,
place the dihedral gauge on the centerline as shown and
mark the frontspars, main spars, TE sheeting and TE.
Mark the LEatthe side of rib #1A.
NOTE: You may need toadjustthe pre-cutslotsto
provide enough clearance forthe wing joiner to slide.
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D3. Drill a 1/8" hole at the punch mark on rib #1A.
D4. Center rib#1A againstthe LEand on the line drawn
on the1/8"plywingjoiner.Make surethatrib#1Ais
centered between the edges of the plywing joiner. Using
theholethroughrib#1Aas a guide,drilla 1/8" hole,
perpendicularto rib#1A,5/8" deep into the LE.
D5.Starting atstep 2, repeat for the leftwing panel.
D6.Onthe Easy Sport 60,alignrib#1A on the right
wing panel and insertthe1/8" x 1" alignmentdowel
through rib #1Aand into the LE.Atthis point test fitthe
left and right wing panels together "dry" (NO GLUE) on
the Easy Sport 40 and 60. With the center of the wing
resting on the work surface, block upboth wing tips 1"
(1-7/64" on the Easy Sport 60) as measured fromthe
worksurfacetothebottomofrib #7 (rib#6 on the
Easy Sport 60). Check the fitof the LE, spars and TE to
make suretheymeet upnicelywithoutany gaps or
sweep inthe wing.
NOTE:Take your time to make sure that thisprocedure
isdone accurately. A littleextraworkand attentionto
detail here will insure a strong, straight wing.
D7.IMPORTANT: Donot useepoxy with a working
timeof less than30 minutes forthisstep!Place
waxedpaper on theworksurfaceand mixup some
epoxy.On theEasySport40,applyittothespar
joiners,spar ends and the ends of bothleading and
trailing edges. Onthe Easy Sport 60,apply epoxy to the
spar joiners,spar ends, theends of both leading and
trailingedges, the 1/8" hole inthe leading edges and the
aft edge of rib#1 A where itcontacts the ply wing joiner.
On both the Easy Sport 40 and 60, slide the spar joiners
into the right wing panel first.Slide the leftwing panel
into place and wipe off any excess epoxy. Immediately
proceed to the next step.
D8.Block upthe tips of both wing panels 1"on the
EasySport40(1-7/64"ontheEasySport60)as
measured fromthe work surface to the bottom of rib #7
(rib #6 on the Easy Sport 60). Carefullyalign the spars,
LEand TE of both wing panels. Clamp the spar joiners
to the spars and wipe off any excessepoxy witha paper
towel.Allow the epoxy to fully cure before disturbing
the wing and removing the clamps.
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D9. Securely glue the remaining balsa shear webs to
the frontand back sides of the spar joinersbetween ribs
#4 and #5 (ribs #2 and #3 forEasy Sport 60). Trim the
shear webs so that they do not protrude above or below
the spar joinerwhere they will interfere with the center
sheeting applied ina later step.
D10. Glue thedie-cut1/8" ply TE Brace in place
between the #2 ribs as shown on the plan.
Ifyou are building the Easy Sport 60, skip to step 6
under Install the center ribs and sheeting.
D1.Mark the center of the front LEjointwith a pencil.
VerticallycentertheremainingLEjoineron themark
and tack-glue inplace. Then. using both LEjoinersas
guides, drill through the frontLEjoiner, shaped LEand
back LEjoinerwitha 1/4" drill. Remove only the LE
joiner that istack-glued to the front of the LE.
D11. Witha pencil, mark the back of the LEcenter
joint: 3/32" and 3/8" down fromthe top of the LE.Also,
3/32"upfrom thebottom of the LE.See photo.
D2. Round both ends of the pre-cut,3" long wing
dowel with medium (150-grit) sandpaper.
D3.Install the previously laminated 1A ribs asshown
on the plans (do not glue yet.) Slide the wing dowel
through the LEand allthe way into the slot inrib1A.
D12. Center a die-cut 1/8" ply leading edge joineron
the back of the LEcenter joint. Use the marks drawn in
the previous step to aidinalignment. Glue inplace with
thin CA.
D4.Align the 1A ribs and the wing dowel so that the
wing dowel isflushwith the outside edges of the slot in
1A.Glue 1A totheLE and forwardsparjoinerwith
medium CA. Becareful not to glue inthe wing dowel.
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D5.Remove the wing dowel fromthe wing. Mix upa
batchof 30-minute epoxy. Apply the epoxy to the inboard
side of both die-cut 1/8" ply 1B ribs. Install the 1Bribs as
shownontheplans,liningthemup withthe1A ribs
(Remember: the embossed "T" identifiesthe top of the
rib). Quickly pack some epoxy into the wing dowel hole in
the LEand insert the wing dowel all the way into the wing
dowel hole. Clamp the 1A and 1B ribs together. Donot
disturb the wing until the epoxy hasfully cured.
D7 If youare building the Easy Sport 40, edge glue
(proceduredescribedbelow)twoofthe3/32"x3" x
7-1/4"and the3/32"x 1-3/4"x 7-1/4"balsacenter
sheeting pieces together using thinCA. This assembly is
now the top center sheet. Glue the remaining two3/32"
x3" x 7-1/4" balsa sheets together inthe same manner.
This assembly isnow the bottom center sheet.
Ifyou are building the Easy Sport 60, locate the
five3/32" x 3" x 24" balsa sheets. From these sheets,
cut ten pieces 10-7/8"long.Cut one of thesepieces
2-3/4"wideand anotherone5/8"wide.Edge glue
(proceduredescribedbelow)twoofthe3/32"x 3" x
10-7/8" and the 3/32" x 2-3/4" x 10-7/8" balsa sheeting
pieces together using thin CA. This assembly isthe top
center sheet. Edgeglue the remaining two 3/32"x 3"x
10-7/8" and the 3/32"x 5/8" x 10-7/8" balsa sheeting
piecestogetherusing thin CA.This assemblyis the
bottom center sheet.
D6. Locate the previously laminated 1Cribs.Slide 1C
into positionbetweentheaftspar joinerand theTE
brace as shown. You may have to trim 1Cto length for it
toproperlyslideintoplace.Maintaina 3/32"gap
between the bottom edge of the rib and theworksurface
to allow forthecentersheetingwhichwillbe installed
later.Usea leftoverpiece of 3/32" balsa to hold the rib
upoffthe worksurfaceduringthisstep. Hold inthis
position andglue inplacewith thin CA.
18

Lt8.Fitthe top center sheet inplace on the top of the
wing. Itsposition isaft of the main spar. Trim or sand, if
required, fora good fit.The sheet should fitinto the rails
createdat thejointofribs#3 and #4.Donot glue.
Repeat this step to fitthe bottom center sheet.
D11.Slide thetwodie-cutply aileron servo tray
supports inplace. Donotgluethem inyet.
D9.Place the top center sheet into position. Turn the
wing over so that the bottom isfacing up. With moderate
finger pressure, squeeze the sheet so that itcontacts the
top of rib #1C. Holding itinthis position, glue the center
sheet to rib #1C with thin CA. Work the pressureevenly
along 1C so thatthere are no gaps while gluing. Inthe
same manner, glue the center sheeting to the #2 and#3
ribs. Now, examine allcenter section jointsand apply
medium or thick CA to any questionable areas.
D12.Install the die-cut ply aileron servo trayin place
on topoftheaileronservotraysupports.When
everythingis inposition,glue the servo traysupports
andservo tray inplacewith thin CA.
D10.Using a hobby saw or knife, remove thepartiallycut
brace from rib#1C. At this pointtest fitone of your servos
intothe pocketjust created. Ifitfits,great! Ifnot, now isthe
timetoenlargethecutout.Thisis mosteasily
accomplishedwitheither a hobby saw or a Dremel
MultiPro.
D13. Test fitthe bottom center sheet one last time.The
bottom sheeting will beinstalled directly over the servo
tray.Remove the sheet and apply thickCA to the ribs
and servo tray. Press the sheeting down and hold itin
place until the glue sets.
19

D15On the Easy Sport 40, cut the remaining 3/32" x
3" x 7-1/4" balsa center sheet pieces in half as shown.
Custom fiteach piece to fitinthe fourremaining upper
and lower forwardcenter sections asshown Glue these
pieces securelyinplace Onthe Easy Sport 60, custom
fitthe remaining four10-7/8" pieces to fitinthe four
remaining upper and lower forwardcenter sections as
shown Glue these pieces securely inplace.
D14.With a pencil, draw a linefrom the joint of the bottom
spars to the jointof the bottom TE sheeting This isthe
centerline of the wing Measure back fromthe aft edge of
the bottom spar and make a mark 3/8" and 2-5/8" (5/8" and
2-7/8"onthe Easy Sport 60) Now,make a mark 7/16" on
each side of the centerline This isthe basic cutout forthe
aileron servo trayUsing your servo,adjust the size of the
holeappropriatelyforproperfitandclearance.
D16.Usingmedium (150-grit) sandpaper, sand the top
and bottomcenter sectionsto smooth out theseams
and even upthe center sheeting You may wish to use a
lightweight hobby fillersuch as Hobbico Hobbylite" to
fillinany slight gaps.
20