GREAT PLANES F-4 Phantom II User manual

INSTRUCTION MANUAL
WARRANTY
GreatPlanesModel ManufacturingCo.guaranteesthiskittobe freefromdefectsin bothmaterialand
workmanshipat thedate of purchase.This warrantydoesnot coverany componentpartsdamaged 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 warranty without notice.
Inthat Great Planes hasnocontrol over the final assembly or material used forfinal assembly, no liabilityshallbe
assumed nor accepted forany damage resulting fromthe use bythe user of the final user-assembled product. Bythe
act of using the user-assembled product, the user accepts allresulting liability.
Ifthe buyer isnotprepared to accept the liabilityassociated with the useof this product, the buyer isadvised
to return this kitimmediately innew and unusedcondition to the place of purchase.
While this kit has been flighttested to exceed normal use, if the plane willbeused forextremely high stress flying, such
as racing, the modeler isresponsible fortaking steps to reinforce the high stress points.
READTHROUGHTHISMANUALBEFORE
STARTING CONSTRUCTION. ITCONTAINS
IMPORTANT WARNINGS AND INSTRUCTIONS
CONCERNING THE ASSEMBLY AND USE OF
THIS MODEL.
©copyright 1997
P.O.Box788Urbana,IL61803(217) 398-8970
F460P03 V1.0

Introduction .....................................................................3
Precautions......................................................................3
Decisions You MustMake...............................................3
Engine Selection.........................................................3
Wheel Selection.........................................................3
Preparations ....................................................................3
Required Accessories.................................................3
Optional Retracts.......................................................4
Building Supplies and Tools........................................4
Optional Supplies and Tools .......................................4
Types of Wood............................................................5
Common Abbreviations...............................................5
Building Notes.............................................................5
Get Ready to Build......................................................5
Die-Cut Patterns...................................................6& 7
BuildtheTailSurfaces....................................................8
Buildthe Stabilizer......................................................8
Build the Elevator........................................................8
Build the Fin................................................................8
Buildthe Rudder.........................................................9
Hingethe Tail Surfaces...............................................9
Finish the Tail Surfaces.............................................10
Fitthe Torque Rods...................................................10
Build the Wing ...............................................................12
Wing Preassembly....................................................12
Build the Main Wing Panel........................................13
Installthe Landing Gear Blocks................................15
Sheet the Bottom of the Wing...................................15
Sheet the Top of the Wing.........................................17
Complete the Wing Middle Section...........................18
Build the Wing Tips...................................................20
Join the Wing TipsTothe Wing.................................22
Buildthe Ailerons..........................................................22
Install the Ailerons.....................................................23
Build the Fuselage ........................................................23
Fuselage Preassembly .............................................23
Assemble the Fuselage Sides ..................................24
Install the Formers....................................................25
Sheet the Turtle Deck ...............................................27
Finish the Fuselage Bottom ......................................29
Mount the Engine......................................................30
Mount the Wing.........................................................31
Install the Stabilizer...................................................32
Install the Fin............................................................33
Assemble the Splitter Plates.....................................33
Build the Belly Pan....................................................34
Cut the Wheel Wells .................................................35
AssemblethePlasticParts..........................................35
Assemble the Nacelles .............................................35
Assemble the Radio Hatch .......................................36
RadioInstallation..........................................................37
Install the Rudder, Elevator & Throttle Servo............37
Install the AileronServo ............................................39
BalancetheModelLaterally.........................................40
Covering.........................................................................40
Prepare the Surface..................................................40
Covering Technique..................................................40
Suggested Covering Sequence................................40
Painting..........................................................................41
FinalHookupsandChecks..........................................41
Install the Hinges ......................................................41
Install the MainRetract Servo...................................42
Attach the Wing Tips.................................................43
Install the Hardware.................................................43
Attach the Canopy & Splitter Plates..........................44
Setthe Control Throws.................................................44
Balance Your Model..................................................45
Preflight..........................................................................45
Charge the Batteries................................................45
Balance the Propeller ...............................................45
Finda Safe Place to Fly............................................46
Ground Check the Model..........................................46
Range Check Your Radio .........................................46
Engine Safety Precautions .......................................46
AMASafetyCode...........................................................46
General....................................................................46
Radio Control...........................................................47
Flying..............................................................................47
Takeoff......................................................................47
Flight.....................................................................47
Landing....................................................................47
2-View Drawing.............................................................48
Your F-4 Phantom isnot a toy, butrather a sophisticated,
workingmodel thatfunctionsverymuch likea fullsize
airplane.Becauseofitsrealisticperformance,the F-4
Phantom,ifnotassembledand operatedcorrectly,
could possibly cause injury to yourself or spectators and
damage property.
Ifthis isyour firstlow wing sport model, we recommend
thatyouget help froman experienced,knowledgeable
modeler with your firstflights. You'll learn fasterand avoid
risking your modelbefore you're ready to takethe controls
foryourself.
For informationon flyingclubs inyourarea,youcan
contact the national Academy of Model Aeronautics (AMA),
whichhas more than2,300 charteredclubsacrossthe
country.ContactAMA atthe address or toll-freephone
number below:
Academy of ModelAeronautics
5151 East Memorial Drive
Muncie, IN47302-9252
Tele. [phone]
Fax [phone]
Orvia the internet at: http://www.modelaircraft.org
2

The GreatPlanes F-4 Phantom is a high performance
propeller-driven sport airplane that closely resembles the
full size F-4 Phantom. Inthe air,the prop isinvisible, adding
to the realism. The smoothness and speed of this airplane
allow you to experience the thrillsof flyinga jet-likeairplane
without the complexity and high cost of a ducted fan model.
The F-4 Phantom isverystable and forgiving,allowing
even intermediate skilllevel pilotsto enjoy it.
This isnota beginner's airplane! While the F-4iseasy to
buildand fliesgreat,wemustdiscourageyoufrom
selectingthiskit as your firstR/C airplane.Itlacks the
self-recoverycharacteristics of good basic trainers such as
the Great Planes PT"Series.On the otherhand, if you
have already learned the basics of R/C flying,and you are
able to safelyhandle a .60-size low wing airplane, the F-4
Phantom isanexcellent choice to tryyour skills atflying
a jet.
1.You mustassemblethemodelaccordingtothe
instructions. Do not alter or modify the model, as doing so
may result inan unsafe or unflyable model. Ina fewcases
the instructions may differ slightly from the photos. Inthose
instancestheplansand writteninstructionsshould be
considered as correct.
2.Take time to buildstraight, true and strong.
3.UseanR/C radio system that isinfirst-class condition,
and a correctly-sizedengine and components (fuel tank,
wheels, etc.) throughout your buildingprocess.
4.You must properly install allR/C and other components
so that the model operates properly on the ground andin
the air.
5.You must test the operation of the model before every
flight to insure that allequipment isoperating, and you must
make certainthatthemodelhas remainedstructurally
sound. Besure to check clevises or other connectors often
andreplace them if they show signs of wear or fatigue.
Pleaseinspectallpartscarefully before starting to build!
Ifany parts are missing, broken ordefective, orifyou
haveanyquestionsaboutbuildingor flyingthis
airplane, please call us at [phone]. Ifyou are
callingfor replacementparts, pleasereference the part
numbersand thekitidentification number(stamped on
the endof thecarton) andhave them readywhen calling.
Engine Selection
There are several enginesthat willwork well inyour F-4
Phantom, but forunlimited performance we recommend
ahot 2-stroke such as an O.S. .61FX or SuperTigre""
G61. The engine you select will determine how youbuild
the fuselagenose section,so itisimportant thatyou
have the engine close athandwhile building. Because of
the size limitations and the nature of this model, 4-stroke
engines are more difficultto installand balance and
therefore are notrecommended.
Wheel Selection
Large wheels lookunrealistic ona modelof this type, so
try to keep the wheels as small as possible. Ifyou will be
flyingfrom a concrete or asphalt runway, we recommend
2-1/2" main wheels and a 1-3/4" nose wheel. For grass
fields, larger wheels will berequired, such as 2-3/4" main
wheels anda 2"to 2-1/4" nose wheel.
PREPARATIONS
Required Accessories
Items in parentheses (GPMQ4243) are suggested part
numbers recognized by distributors and hobby shops and
are listed for your ordering convenience. GPM is the Great
Planes brand, TOP is the Top Flite brand and HCA is the
Hobbico' brand.
NOTE: We, as the kit manufacturer,can provide you
with a top quality kit and great instructions, but ultimately
the quality of your finished model depends on how you
build it;therefore,wecannotin any wayguarantee
theperformanceofyourcompletedmodel,and no
representationsareexpressedor impliedas tothe
performance or safety of your completed model.
Remember: Take your time and follow directions to end
upwith a well-built modelthat isstraight and true.
Four-channel radio with fiveservos (seven if
mechanical retracts are used)
Engine - See Engine Selection above
Propeller (Top Flite Power Point™); Referto your
engine's instructions forproper size
Fuel tank 10oz.- 12oz. (GPMQ4104 andGPMQ 4105)
Medium fueltubing (GPMQ4131)
2-1/2" Main wheels (GPMQ4223)
2" Nose wheel (GPMQ4221)
Top FliteMonoKote' (Approximately 3 rolls)
3

1-1/2" pilot figure (Williams Bros. #171)
Latex foam rubber padding (HCAQ1050)
Switch and charge jack(GPMM1000)
Top Flite LustreKote" Paint - See Painting (page 42)
1/16" wing seating tape (GPMQ4422)
Silver solder (GPMR8070)
6"servo extension
3" Black spinner (GPMQ4531)
5/32" wheel collars (GPMQ4306)
3/16"wheel collars (GPMQ4309)
Standard Servo
Mixer
(Requires one set of MainsandNoseGear.)
PneumaticRetracts
Robart 605HD Pneumatic Retract Mains
Robart 607 Pneumatic Retractable Nose Gear
Robart 188AirControlKit
3/16" Adjustable Axlesforthe MainRetracts
(GPMQ4282)
5/32" AdjustableAxles forthe Nose Gear
(GPMQ4281)
3/16" Wheel collars(GPMQ4308)
5/32" Wheel collars (GPMQ4306)
Minior Micro servo
2oz. ProCA (Thin,GPMR6003)
2oz. Pro CA+ (Medium, GPMR6009)
1oz. Pro CA- (Thick, GPMR6014)
6-Minute Pro Epoxy (GPMR6045)
30-Minute Pro Epoxy (GPMR6047)
Hand or electric drill
Sealing iron (TOPR2100)
Heat gun (TOPR2000)
Hobby saw
Hobby knife,#11 Blades
Razor plane (MasterAirscrew®)
Pliers (Common and Needle Nose)
Screwdrivers (Phillips andflattip)
T-pins(HCAR5150)
60" Retractable Tape Measure (HCAR0478)
Straightedge with scale
Masking tape (TOPR8018)
Sandpaper (coarse, medium, finegrit)
Easy-Touch'" Bar Sander (or similar)
PlanProtector (GPMR6167)
Lightweight balsa fillersuch asHobbico®
HobbyLite'" (HCAR3400)
1/4-20 Tapand Drill (GPMR8105)
IsopropyI rubbing alcohol (70%)
White body putty (Squadron SQUR1500)
Ballpoint pen
90° Building square (HCAR0480)
Micro balloons (TOPR1090)
Canopy glue
Drill bits: 1/16", 1/8",3/16" (Long Bit),5/64", 9/64",
13/64", 3/32", 5/32", 1/4", 7/64", 3/16"
Thesearethebuildingtoolsthatarerequired.We
recommend Great Planes Pro" CA and Epoxy glue.
RobartMechanicalRetracts
Robart 608HD Mechanical Retract Mains
Robart 610 Mechanical Retract Nose Gear
3/16" Adjustable Axles for the MainRetracts
(GPMQ4282)
5/32" Adjustable Axlesfor the Nose Gear
(GPMQ4281)
3/16" Wheel collars (GPMQ4308)
5/32" Wheel collars (GPMQ4306)
Retract servoand Standard servo
48" Nylon pushrod
Screw-Lock Pushrod Connectors (GPMQ3871)
CA Applicator Tips (HCAR3780)
Epoxy brushes (GPMR8060)
Epoxy mixing sticks (GPMR8055)
CA Debonder (GPMR6039)
HotSock"'(TOPR2175)
Single-edge razor blades (HCAR0312)
Duratrax Curved Scissors fortrimming plastic
parts (DTXR1150)
4oz. Pro Wood Glue (GPMR6161)
Milledfiberglass (GPMR6165)
4

On our workbench,we have three11"Great Planes
Easy-Touch Bar Sanders, equipped with80, 150 and
220-grit sandpaper. This setup isall that isrequired for
almostanysandingtask.Wealsokeepsome
320-gritwet-or-drysandpaper handy forfinish sanding
before covering.
Great PlanesEasy-Touch BarSanders are made from
lightweight extruded aluminum andcan befound atmost
hobby shops. They are available infivesizes - 5-1/2"
(GPMR6169)forthosetight,hardtoreachspots;
11"(GPMR6170) formost general purpose sanding; and
22" (GPMR6172), 33"(GPMR6174) and44" (GPMR6176)
forlongsurfacessuchas wingleadingedges.The
Easy-Touch adhesive-backedsandpaper comesin
2"x 12'rolls of 80-grit (GPMR6180), 150-grit (GPMR6183),
180-grit (GPMR6184) and 220-grit (GPMR6185) andan
assortment of 5-1/2" longstrips (GPMR6189) for the short
barsander. The adhesive-backed sandpaper iseasy to
apply and remove from your sandingbarwhen it'stime
for replacement.
Custom sanding blocks canbemadefrom balsaorhardwood
blocks anddowels forsanding difficultto reach spots.
Sheet metal screws are designated
by a numberand a length.For
example #6 x 3/4"
Machine screws are designated by
anumber,threadsper inch and a
length. For example 4-40 x 3/4"
When you see the term "test fit"inthe instructions,it
means youshould firstposition the part on the assembly
without usingany glueandthen slightly modify or sand
the partasnecessary for the bestfit.
Whenever the instructions tell you to gluepieces together,
CA or epoxymay beused. When a specific type ofglue is
required, the instructions willstate the type of glue that is
highly recommended. When 30-minute epoxyis specified,
itis highly recommended that youuse only30-minute (or
slower)epoxybecause youwillneed either the working
time or the additional strength.
Several times during construction we refer to the "top"or
"bottom" of the model or a part of the model. For example,
during wing constructionwe tellyou to "glue the top main
spar" or "trim the bottom of the former." Itisunderstood that
the "top" or "bottom" of the model isas itwould bewhen the
airplane isright side upand will bereferredto as the "top"
even ifthe model is being worked on upside down. (i.e. the
"top" main spar is always the "top" main spar,even when
the wing isbeingbuiltupsidedown).
There are two types of screws used inthis kit:
1.Unroll the plan sheets. Reroll the plan sheets inside
Balsa Basswood Plywood
out to make them lie flat.The two-part plan willneed to be
cut along the dashed line and taped together. Place wax
paper orGreatPlanesPlan Protectorover the plan to
prevent glue fromsticking to the plan.
2.Remove allparts fromthe box. As you do, determine
the name of each part bycomparing itwith the plan and
thepartslist includedwiththiskit.Usinga felt-tipor
ballpoint pen, lightly writethe part name or size on each
piece toavoidconfusionlater.Use thedie-cutpatterns
shown on pages 6 and 7 to identify the die-cut parts and
mark them before removing them fromthe sheet. Save all
scraps. Ifany of the die-cut parts are difficultto remove, do
not forcethem!Instead, cut around theparts.Use your
Easy-Touch Bar Sander or sanding block to lightly sand
the edges to remove any die-cutting irregularities.
3.As you identify and mark the parts, separate them
Elev = Elevator
LE= Leading Edge(front)
Ply = Plywood
TE = Trailing Edge (rear)
Fuse= Fuselage
LG= Landing Gear
Stab= Stabilizer
"= Inches
intogroups,suchas fuse(fuselage),wing,fin,stab
(stabilizer)and hardware. Resealable foodstorage bags
arehandytostorepartsin as yousort,identifyand
separate them into subassemblies.
5

DIE-CUTPATTERNS
6

7
DIE-CUTPATTERNS

top andbottom surface of the stab untilitisflat andeven.
Becareful not to sand any area of the stab too thin.
1.Glue the shaped 3/8" balsa forward and aft stab
1.Cut a 10-1/2"long piecefromtheshaped
togetherovertheplan.MakethestabLE froma
3/8" x 1/2" x 24" balsa stick.Glue thestab LE to the
forward stab.
3/8" x 1-1/4" x 30" balsa elevator TE. Glue the shaped 3/8"
balsa elevator LEto the 10-1/2"longTE.
2.Trimthe ends of the elevator TE to match the plan
Note: Refrain from usingexcessive accelerator. Hours
afterit'ssprayedon, residualacceleratorcan
prematurely and unexpectedly cure the CA you use later,
on nearby glue joints. Unless you must handleor remove
thepartfromyourbuildingboardrightaway,we
recommend using noaccelerator atall.
2.Cutthestab tipfrom the3/8" x 1-3/8"x 15"balsa
and sand the top andbottom to the shape shown on the
elevator cross-section.
3. Tape the LEof the elevator to the TE of the stab.
Sand the stab tip to match the angle of the elevator.
4.Gobackto step 1 of Build the Stabilizers andbuildthe
second stab andelevator following the same procedure.
stick and glue itto the end of the stab.
3. Cut a 1/8"x 1"notchinthe rootof the stab,as
shown on the plan.
shown on the plan.Useyour barsander to sandthe entire
1.Glue the shaped 3/8" aft,forwardand dorsal fin
together over the plan. Make the fin LEfroma 3/8" x 1/2"
balsastick. Gluethe fin LEto the dorsal andforward fin.
4. Sand a radius on the corner of the stab tip as
8

2.Cutthe fin tip from the remaining 3/8" x 1-3/8"balsa
stick. Glue the fin tip to the top of the fin. C. Use playing cards or business cards to adjust the
height of the pen until you can mark the centerline.
3.Sand a radius on the corner of the fin tip as shown on
the plan.Sand both sides of the finuntil they are flat and
even. Becareful not to sand any area of the fintoo thin.
1.Gluethe shaped 3/8" balsa rudder LE to the tapered
3/8" balsa TE. Trim and sand the TE to the same length as
the LE.Draw a centerline on the LEof the shaped 3/8"
balsarudder(see the expert tip below). 2. Set the rudder on its LE and use the parallel line
method to draw a line5/32" from the LE,on the sides of
the rudder.
HOW TOMARK PARALLEL LINES
the rudder cross-section.
3.Sanda taper on both sidesof the rudderas shown on
It'simportant that the centerlines and"bevel to" linesare
parallel to the edge of the part.
4. Tapethe rudder inposition on the TE of the fin. Sand
ataperon the fintipto match the taper on the rudder.
A.Positiontherudderand a ballpointpen on a flat
surface. Mark a "test line" onthe LEof the rudder.
B.Fliptherudder overand mark another line inthe
same location as the first.Ifyou see only one line, then it
ison center. Proceed and mark the centerline on the
LE. If yousee twolines,youwillhave toadjustthe
heightof the pen until you can mark the centerline.
plan and lightly mark the hingelocations on the TE of the
stab andLEof the elevator.
and elevator'sLEusing the parallel lines method described
inthe previous expert tip.
1.Place the stab and elevator over their locations on the
2.Mark the centerline of the hinges on the stab's TE
9

3.Cut the hingeslots inthe elevator and stab using a
#11 blade.Begin by carefully cutting a veryshallow slit at
the hinge location to accurately establish the hinge slot.
Make threeor fourmore cuts, going a littledeeper each
time. Asyoucut, slide the knife fromside to side until the
slot has reached the proper depth andwidth forthe hinge.
4.Cutthe hinges forthe elevators andrudder from the
supplied 2" x 9" hinge material. Use the hinge drawing
on thefuseplan as a guide.Trimoffthecornersand
temporarily join the elevators to the stabs withthe hinges,
adjusting any hinge slots if necessary. Donot glueinthe
hinges untilyou are instructed to doso.
5. Returntostep1 and use the same procedure to
hingethe rudderandfin.
of the elevatorsand rudder to a "V"shape as shown on
the plan.
CUT HINGE SLOT
WITH HOBBY KNIFE
AND #11 BLADE
1.Refer to the Expert Tipthat follows andshape the LE
B.Using the bevel to lines andthe centerline as a guide,
makethe "V" on the leading edge of the elevators with a
razor planeor your barsander.
2.Usethe sameprocedure to bevel the leadingedge of
the rudder.
3.Drawa centerline onthe LEandtipof the stabs,and
on the fin'sLEand tip. Sand a radius on the edges as shown
on the planusing the centerline as a guide to keep the radius
symmetrical. Do notround the TE of the stab or fin.
1.Position the stabs over the fuselagetop view. Mark
the locationof the torque rodbearings onthe stabs.
2. Cut a slot in theTE of the stabs forthe tab on the
torque rod bearings. Temporarily install the torque rods in
the stabs.
HOW TO BEVEL THE LEADING EDGE
A. Placethe leading edgeof one of the elevatorson
your work surface and use your ballpoint pento mark a
"bevel to" lineon both sides about 1/8"high.
Note:You will probably have to adjust the height of the
elevator with card stock (as you did while marking the
centerline) so your "bevel to" lineisnottoo high- making
too sharp of a "V."3. Withthestabspositionedon theplan, align the
elevators andmark the location of the torque rods.
10

4. Drill a 3/32" pilot hole, into the elevator LE,atthe
centerline and torque rod mark. Asyou drill the holes keep
the drill aligned withthe top and bottomsurfacesof the
elevator. Enlargethe holes with a 1/8"drill.
5. Cut a 1/8" groove inthe leadingedge of bothelevators
to recess the joiner wire (see expert tipthat follows).
7.Mark the centerlineon the LE of the shaped 3/8"
balsalowerfinextension.Cuta groovealongthe
centerlineforthe rudder torque rod bearing. The groove
must bedeep enough to encase the torque rod bearing.
HOW TOCUT A GROOVE FOR A TORQUE ROD
A. Usea hobby knife to sharpen the insideof a pieceof
1/8"brass tube. Roll the tube as you carve the end.
8. Roughenthetorquerod bearingwith80-grit
sandpaper. Insert the bearing inthe groove inthe LEof the
lower finextension andglue the extension to the TE of the
fin, asshown on the plan.
9.Position the finandrudder over the planandmark the
location of the ruddertorque rod.
10.Drillandgroove the rudderLEfor the ruddertorque
B.Use the sharpened tube to carefully gouge the leading
edge. You'll have to make a fewcuts to make the recess
deep enough forthe torque rod.
rod, followingthesameprocedureused previouslyfor
the elevator.
11.Sand a taper on the lower fin extension using the
rudder as a guide.
6.Cut a notch inthe stab TE to allow the torque rod to
pivot freely.
11

1.Cutfourofthe1/8"x 3/8"x 29-7/8" basswood spars to
Retract Gear
4. Skipto step 5 ifyou are notinstallingretracts. If
you chose to install retracts, use 30-minute epoxy to glue
the die-cut 1/8" plywood ribdoublers R-4R to the die-cut
1/8" balsa ribs R-4 and the die-cut1/8" plywoodrib
doublers R-5R to the die-cut 1/8" balsa ribs R-5. Be
sure to make a right and leftof each ribassembly.
18"longsubspars. Fromthe remaining 1/8"x 3/8" x 29-7/8"
basswood spars cut four,10" long sub spars. Save the
leftover sparmaterialfor uselater.
1-1/2"
2.Sanda 1-1/2" long taper onone end of each 10"and
18"longsub spar.
5. Skipthis step ifinstalling retracts. Use 30-minute
epoxy to glue the die-cut 1/8"ply ribdoublers R-3F to the
die-cut1/8" balsa ribs R-3 and thedie-cut1/8" ply rib
doublers R-5F to the die-cut 1/8" balsa ribs R-5. Besure
to make a right and leftof each rib assembly.
6.Cut notches inthe balsa ribsto match the notches in
the plywood rib doublers. Ifinstalling the fixedlandinggear,
alsocut the notch atthe TE of R-3.
7.Use30-minute epoxy to glue the die-cut1/8"balsa
ribsR-1 together.
3/8" 3/8"
3/16"
3/16"
3. Make four main spars by gluing a 29-7/8",18"and
10"sub spar together with medium or thick CA. Makesure
the sides andsquare ends are flush.
Note:Besure the spars are flat andstraight.
8.Make the center TE plates byusing30-minute epoxy
to glue a shaped3/16"balsa center plate betweena
shaped 3/8" and 1/2" balsa top and bottom center plate.
Make sure to align the ends and the long straight edge.
This will produce a notch atthe front forthe aileron torque
rods. Maketwo center TE plates.
12

The main wing is built as one assembly, upside down over
the wing plan.
1.Cover the wing plan with wax paper or Great Planes
Plan Protector. Trim the 3/8" x 3/8" end of two main spars
to the angle shown on the plan. Use 6-minute epoxyto glue
the ends of two of the main spars together. Pin the main
spars (longest spar against the buildingboard) over the
wing plan.5.Insert the 1/16" plywood center plate inthe notch in
2.Gluethe shaped 3/8" balsa spar joiner to both main
spars with 30-minute epoxy.
ribR-1.Trim the 3/8" x 3/8" end of the two remaining main
spars, atan angle, so they fitagainst each othersimilar to
the top spars (remember the wing is built upside down).
Also, check that the spar isflush with the bottom edge of
the wing ribs.
6. Fitthe balsa spar joinerbetween the bottom main
spars,inthe notch of ribsR-1.
7.Test fitthe die-cut 1/8"balsa sub front cap to the
front of ribsR-1 andR-2.
3.Use30-minute epoxy to gluethe die-cut 1/16" plywood
centerplateover the mainspars andthe sparjoiner.
4. Pin the die-cut wing ribsR-1, R-2, R-3, R-4, R-5, R-6,
R-7 and R-8 inposition over the main spar, perpendicular
to the building board. The notches inthe ply rib doublers
will needto beenlarge slightly to allow the main spars to fit.
Donotglue the ribs untilinstructed to doso.
Note: The jigtabs should be contactingthe plan. Use
small T-pins to pinthe aft jig tabs to the building board
over their location on the plan.
8. Test fitthe die-cut 1/8"balsa sub trailing edgeto the
aft end of the ribs. The root end of the sub TEs will need to
bebeveled fora good butt joint.
9. Makesurethe top mainspar,wing ribsandjig tabs
are securely pinned to yourbuilding board. Glue the ribs
perpendicular to the top mainspar.
10.Usea straightedge and building square to keep the
parts straight and perpendicular as you glue the balsa sub
front cap to the frontand the sub trailing edge to the aft end
of the ribs.
13

11.Use 30-minute epoxy to glue the center plate inthe 15.Trim and glue 3/32" x 2-1/4" x 3"balsa shear webs,
notch of rib R-1,bottom main spars and spar joiner. Place
apiece of waxpaper overtheassemblyat rib R-1and
weight the bottom main spars down. While the epoxy isstill
wet,use thinCA to glue the bottom main spars to the ribs
startingat rib R-8and workingtowardR-2.The bottom
main spar should beflush with the bottom of the wing ribs,
and the center plate will bebent down slightly on each side
of ribsR-1.
perpendicular to thefrontof the main spars. The shear
webs must beglued securely to the mainspars.
16.Sandthe aft endof the wing ribsflush with the subTE.
12. Sand the ends of the balsa sub frontcap to match
the sweep of the wing. Test fitthe shaped balsa leading
edge on the front of the wing ribs.The sub front capwill
need to besanded an additional 1/16" to compensate for
the ribs inthe notches of the LE. Make sure that the LEis
straight.
17.Sand the larger ends of the shaped balsa trailing
edges tomatch theangle at ribs F-1.Glue thetrailing
edges flush with the top andbottom of the sub TE.
bygluing atribR-8 working toward R-3.
13.Glue the LE,centered on the front of the ribs.Start
14.Sand the LEflush with the frontof the sub cap.18.Use 6-minute epoxyto glue the die-cut 1/8" plywood
wing dowel braces intothe slot inribsR-2 andR-3.
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Perform steps 1 and 2 only ifinstalling retracts
4. Use 30-minute epoxy to glue the 1/2" x 5/8" x 3/4"
hardwood landing gear torque blocks to the top side of the
main blocks and the plywood sides of rib R-3. Glue the 5/8"
hardwood landinggear gussets to the mainblock andthe
plywood sides of ribR-5.
1.Use 30-minute epoxy to glue the 1/4" x 3/4" x 3-5/8"
plywood retract mounting plates into the notches inribs
R-4and R-5.Beforetheepoxycures,glue the5/8"
hardwood landing gear gussets under the front mounting
plates against ribsR-4 andR-5.
andtorque blocks as shown on the plan.This hole must be
drilled perpendicular to the main landinggear blocks.
5.Drilla 13/64" hole through the main landinggear blocks
6.Fitthe 3/16"mainlandinggear struts intothe blocks
2. Fitthe retract mechanism inplace, trimming the
plywood mounting plates as required to allow the retract
to operate properly. Drill 3/32" pilotholes forthe retract
mounting screws and temporarily mount the retracts on
the plywood mounting plates with four #4 x 3/8" sheet
metal screws (not included).
and fillthe unused portion of the slot ateach end of the main
landinggear blockswith leftover balsa.Remove the strut.
1.Checkallofthegluejoints,addinggluewhere needed.
Perform steps 3 though 6 onlyifinstallingfixed gear 2.Sand the bottom of the wing ribs,shear webs, main
spars andTE flush.
3.Place the 3/8" x 5/8" x 7-3/8" hardwood main landing
gear blocks inthe notches inribs R-3 andR-5. Mark and
cut a notch inribs R-4. Use 30-minute epoxyto glue the
main landing gear blocks into the notches, with the groove
facing away fromthe building board.
3. Cut andgluefour 1/16"x 4" x 30"balsasheets, as
shown inthe sketch, to make the top andbottom LEsheets.
15

4.Testfitthe LEwing sheet on the wing. Sand a slight
bevel on the frontof the sheet. The aft edge of the sheet
should cover the forwardhalfof the main spar andthe root
end should cover one of the R-1 ribs.
5. Remove any pins thatare holding the wing to the
10. Sand the TE to match the angle of the ribs. Glue two
1/16"x 1-1/2" x 24" TE sheets to the TE, subTE andthe
bottom of the ribs.
11.Sheet the bottom center section of the wing, fromthe
centerof ribsR-1to R-5,using 1/16"x 3" x 30" balsa
sheets. Repeat the process to sheet the center section on
the other half of the wing bottom.
building board infrontof the main spar. You may need to
set weight on the wing to keep the main spars flat against
thebuildingboard.Positionthefrontof theLE sheet
against the LEandglue itinposition with thin CA.
6.Carefully liftthe sheet away fromthe ribsandapply a
beadof medium or thick CA to the top of the ribs.Working
quickly, pull the sheet back towardthe main spar as you
press itdown against the ribs andthe mainspar.
7.UsethinCA to gluethe sheet to the mainsparand
12.From the 1/16" x 3/8" x 30" balsa stick, cut andglue
sub frontcap.
8.Fitandglue the second LEsheet to the other wing
capstripsto the bottom of ribsR-6, R-7 andR-8. The edgeof
thecapstrip onR-8 shouldbeflush with thesideof the rib.
Hint:A single-edge razor works well forthis type of cutting.
panel,following the same procedure.
9.Trim and sand the LEsheet flushwiththe frontof the
sub front cap.
13. Remove the wingfromyour buildingboard. Cut and
sand the LE, TE, mainspars andbottom sheeting flush with
the sideof ribR-8.
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Perform steps7 though14only ifinstallingretracts
1.Usea hobbyknife and sandingbarto remove thejig
tabs on the top of the ribs. Sand the TE, main spars, shear
webs and the top of the ribs flush.Sand the LEflush with
the bottom forward wing sheeting atribR-8 only.
2.Assemble the two die-cut 1/8" plywood wing crutches
byinserting the crutch bases inthe slots inthe maintip
crutches (MTC).
7.Fromthe top of the wing, useT-pinsto locatethe
main gearretract blocks. Trim the sheeting to fitaround
the retracts.
8.Measure and cut the main retract struts 5-5/8"long
(measured from the surface of the wing).
3.Position the wing on yourbuilding board with the main
tipcrutches under the wing tips atribsR-8. 9.Mount the retracts inthe wing with #4 x 1/2"sheet
4. Placeenough weight on the wing to keep the main
spars incontact with the building board atrib R-1 andribs
R-8seatedin thecrutch.Glue thetopLE sheetingin
position following the same procedure used forthe bottom
LEsheeting.Remember,you previouslymade the LE
sheeting when you sheeted the bottom of the wing.
5.Trim andsand the LEsheeting flush with the front of
metal screws(notincluded). If youare using Robart
Retracts,installa 1-1/4"x 3/16"adjustable axle(not
included, GPMQ4282), 2-1/2" main wheel (not included,
GPMQ4223)and 3/16"wheelcollars(notincluded,
GPMQ4308). The use of various brands of retracts may
require differentor additional hardware. Before tightening
the set screws, check that there isnotoe-in or toe-out
when the retracts are extended.
the subfront cap.
6.Make the twosub TE reinforcementsfromthe leftover
1/8" x 3/8" main spars. Use 6-minuteepoxytoglue the
reinforcements inthe slot inribR-3 andthe subTE.
10.Slowly retract each strut andwheel, cutting away
the bottom sheeting and ribs forclearance. Enlarge the
wheel well to 3",keepingtheholecentered onthe wheel.
17

11.The wheel well liners can bemadefrom foam or
17.Fromthe 1/16"x 3/8" x 30"balsastick, cut andglue
cap stripsto the top of ribs R-5,R-6,R-7 and R-8.The
edge of the cap strip on R-8 should beflush with the side of
the rib.
18.Trim and sand the LEandTE sheeting flush with the
side of ribR-8.
papercups of the proper size, or fromvertical grain 1/16"
balsa sheeting wrapped around an appropriately sized
glass jarand glued to forma cylinder. Glue the wheel
wells inplace andsand the edges flush with the top of
theribsandthe bottom sheeting.
12.Cut a groove inribR-2 andthe wheel well linerfor
the retract actuating rod to pass through. Thread a nylon
clevis (not included, GPMQ3800) 13turns onto the end
of a 2-56 x 12"wire pushrod(not included,GPMQ3750).
13.Connectthe clevis to the retract. Bendthe retract
pushrod to clear the wheel andbebelow the top of the
ribs.Avoid making sharp bends.Remember, the pushrod
will needto beinstalled after the top sheeting isinstalled.
1.Drawacenterline onthe die-cut 1/8"plywoodfrontcap.
2. Use 30-minute epoxy to gluethe front cap to the front
sub cap. Use the centerlines on the front cap as guides to
center iton the frontsub cap.
14.Remove the retracts from the wing.
15.Fitandglue the 1/16"x 1-1/2"x 24" TE sheetto the
TE, sub TE andthe top of the ribs.
16.Sheet the right top center section of the wing from3. Use 30-minute epoxyto glue the die-cut 1/8"plywood
the center of ribs R-1to R-4 using 1/16" x 3" x 30" balsa
sheets. Before sheeting the top left center section, mark the
location forthe aileron andretract servo trays on the top
rightcentersheeting.
4. Sand allthe edges even onthe center TE plate and
the TE of the wing.
18

5.Check the fit of the aileron torque rods inthe slot at
the frontof the center TE plate. Position the plates over the
wing plan.Mark and cut notches inthe 3/8" center plate, to
allow the torque rods to pivot. Test fitthe center TE plates
on the TE of the wing. Sand anangle at the joint between
the twoplates so that the plates align with the wing.
10.Give the wing an overall rough sandingto blendthe
sheeting andcap strips together.
11. Use 30-minuteepoxytoglue thedie-cut1/16"
petroleum jellyto the exposed wire.Use 6-minute epoxy
to glue the torque rod tubes inthe slot at the frontof the
center TE plates. Before the epoxycures, glue the center
TE platestotheTE ofthewingwiththetorquerods
centered on the TE of the wing.
6.Roughen both torque rod tubes and apply a dab of
7.Extend the torque rodexit slots intothe TE of the wing.
8. Trimandsand the center TE plate flushwith the top
plywood wing boltplateto the bottom of the wing, flush with
the aft end and sides of the center TE plate. Use clamps or
weight to hold the bolt platetight against the wing.
center of the wing. We preferto adhere the clothwith thin
CA to save weight, but resin or thinned epoxy willwork well.
Read the following Expert Tipon applyingfiberglass cloth.
and bottom TE sheeting.
12. Apply 2" wide fiberglass cloth to the top and bottom
9. Use the die-cut 1/8"plywood wing LEgauge to sand
the LEto shape. The gauge is held against the LEparallel
to the ribs. Note that the gauge hasa root anda tip shape.
ApplyingFiberglassCloth
A. Center one end of the fiberglass cloth on the LEof the
wing. Apply several drops of thin CA to holdthe cloth
inplace.
B.Roll the loose end on a pencil. Usethe pencil as a
handle to stretch the cloth over the wing toward the TE.
Apply a fewdrops of thin CA to hold the cloth tightly
inposition.
C.Make a squeegee by wrapping a 2"wide pieceof stiff
cardboard with a plastic sandwich bagor similar material.
19

Perform the following operation ina well ventilated
areawithafandirectingtheairflowawayfromyou.
D.Startingatthe LE,flow thinCA intothe cloth. Smooth
the cloth down with the squeegee as you work toward the
TE. Avoidstanding directlyover the work,as the CA
fumes can bequite irritating to your eyes andnose.
E.Allowthe CA to cure naturally without using any
accelerator. When thoroughly cured, lightlysand the
edgeswith 150-grit sandpaperto remove anyedges.
1.Froma 1/8"x 3/8" x 23-7/8" balsasparcut the
forward and aft bottom main spars slightly longer than
thelengthsshownonthewingtipplan.Usethe
cross-pinning technique to pinthe root of the forward main
spar over the wing plan. Place a leftoverpiece of 1/16"
balsa sheet under the tip of the main spar to raise the spar
to meet the notch in the rib. Pin the spar to the building
board. Useleftover balsa to raise the aft sparto meet the
notches inthe rib.Pinthe aft spar to the buildingboard.
13.Place the die-cut 1/8" plywood aileron servo tray
on top of the marks youmade instep 16of Sheet The Top
Of The Wing. Mark the outside perimeter of the tray and
cutthewingsheetingfrominsidethelines.If youare
installing mechanical retracts, perform the same procedure
forthe retractservotray.Ifyouare installing pneumatic
retracts,the controlvalve andmini servo are installed in
the fuselage.
over the plan,perpendicular to the buildingboard.
3.Cut the forward and aft top spars froma second
2.Pinthe die-cut 3/32" balsa ribs T-3 through T-6
14.Glue the die-cut1/8" plywoodaileron servo tray
supports to the middleand ends of the aileron servo tray.
Make sure the supports are perpendicular to the tray. Glue
the servotraydoublers against the supports. If installing
retracts, glue the die-cut 1/8"plywood retract servo tray
supports to the side of the die-cut 1/8" plywood retract
servo tray. Glue the servo tray doublers flush with the end
of the servo cut-out.
15.Trim the balsafrom over the servo locationsinribsR-1.
Gluetheservo trays to the ribs.
1/8" x 3/8" x 23-7/8" balsa stick. Position the forward spar
on the ribs. Use the die-cut 1/8" plywood rib gauge to set
the angle of ribT-2. Place the gauge between ribs T-2 and
T-3 withthe base against the bottom ofrib T-2. With the
remaining ribs perpendicular to the building board andthe
spars seated inthe notches, glue the top and bottom spars
to the ribs.
4.Trim andqlue the 3/32" x 2-1/4" x 3" balsa shear
webs, perpendicular, to the front of the forward mainspars.
5.Move any pinsfrom behindthe aft main spars to in
frontof the aft main spars to holdthe jig tabs against the
building board.
6.From a 1/16" x 3" x 30" balsa sheet, cut a 12" long
TE sheet. Glue the TE sheet to the aft end of the wing tip,
startingatthe front of the aft mainsubspar.
20