GREAT PLANES FUN-ONE User manual

FUN-ONE
INSTRUCTIONBOOK
WARRANTY
Great Planes Model Manufacturing Co.,Inc. guaranteesthis kittobefreeof defects inboth material and workman-
ship at the date of purchase. This warrantydoes not cover any component parts damaged by use or modification. In
no case shall GreatPlanes'liabilityexceedtheoriginalcost of thepurchasedkit.Further,Great Planes reserves the right
to change or modify thiswarrantywithoutnotice.
InthatGreat Planes has no controloverthe final assembly or material used forfinal assembly, noliabilityshallbe
assumed nor accepted forany damage resulting fromthe use by the user of the finaluser-assembled product.
By theact of using theuser-assembled product the user accepts all resulting liability.
Ifthe buyer isnotpreparedto acceptthe liabilityassociatedwith the useof this product,heisadvised
to immediately return this kit innew and unused condition to the place of purchase.
READ THROUGH THIS INSTRUCTION BOOK FIRST. ITCONTAINS IMPORTANT
INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USEOF THIS MODEL.
P.O.BOX 788URBANA, ILLINOIS61801 217/367-2069
FUN1P02

TABLE OF CONTENTS
INTRODUCTION .............3
Precautions ................. 3
Decisions You Must
Make Now ................. 4
Other ItemsRequired ......... 4
Suppliesand Tools Needed .....4
DiePatterns ................. 5
Abbreviations ................ 6
Types of Wood ............... 6
Get Ready to Build ........... 6
TAIL FEATHERS .............6
Buildthe Stabilizerand
Elevators ..................6
Buildthe FinandRudder .......8
Temporarily Installthe Hinges ...9
FUSELAGE ASSEMBLY ...... 10
Prepare Fuse Sides ........... 10
Prepare Firewall ............. 11
Assemble the Fuselage ........ 11
WING ASSEMBLY ...........16
Build the Wing Panels ......... 16
Join the Wing Panels .......... 18
Sheet the Leading Edges ...... 22
Add the Center Sheeting ....... 24
InstallAileron Torque Rods .....25
InstallAilerons ...............26
FINAL ASSEMBLY ...........27
Install Landing Gear ......... .27
Install Engine ................ 27
FitFuelTankand
Fuelproof TankCompartment ..28
MountStabilizer and Fin ....... 29
Install Canopy ............... 30
Build the Wing Fairing ......... 30
Shaping and Sanding .........31
INSTALL PUSHRODS AND
RADIO COMPONENTS ....... 31
One Aileron Servo ............ 31
Two Aileron Servos ........... 31
Rudder, Elevator and
Throttle Servos .............32
Control Surface Throws ........33
Install Receiver, Switch
and Battery ................33
FINISHING.................34
Balance the Airplane Laterally...34
Final Sanding ................ 34
Covering ...................34
Attach the Wing Tips..........34
Glue the Hinges ..............35
Glue Canopy inPlace ......... 35
Wing Seating ................36
Balance Your Model ...........36
FinalHookups and Checks .....36
PRE-FLIGHT ................37
Charge the Batteries ..........37
Finda Safe Place to Fly ....... 37
Ground Check the Model ....... 37
Range Check Your Radio ...... 37
Engine Safety Precautions .....37
AMA SAFETY CODE .........38
FLYING ....................38
Takeoff .....................38
Flying ......................38
Caution ....................39
Landing ....................39
2-VIEW ....................39
PARTS LIST ................40
2

WARNING! THIS ISNOTA TOY!
THIS ISNOTA BEGINNER'S AIRPLANE!
ThisR/C kitandthe model you will buildisnota toy! Itiscapableof serious bodilyharm andproperty
damage. ITISYOUR RESPONSIBILITY AND YOURS ALONE tobuildthis kit correctly, properly install
allR/Ccomponents and flying gear (engine, tank,pushrods, etc.) andtotest the modelandfly itonlywith
experienced, competent help,using common sense and inaccordance with allsafety standards asset
down inthe Academy of Model Aeronautics Safety Code. Itissuggested that you join the AMA andbecome.
properly insured before you attempt to fly this model. IFYOU AREJUST STARTING R/C MODELING,
CONSULT YOUR LOCAL HOBBY SHOP OR WRITE TO THE ACADEMY OF MODEL AERONAUTICS
TOFIND AN EXPERIENCED INSTRUCTOR INYOUR AREA.
Academy of Model Aeronautics
1810Samuel Morse Dr.
Reston, VA22090 [phone]
INTRODUCTION
Congratulations!Thank you for purchasingthe Great
PlanesFUN-ONE!
TheGreatPlanes FUN-ONEdefinesa new typeofsport
airplane.Itssleek looksarc notcharacteristicof the typeof
planes thatare asmaneuvcrableas the FUN-ONE.This
state-of-the-artkitwillprovideyouwithmanyhoursof
enjoymentfromthispointon - even theconstructionis FUN!
Solets begin.
NOTE:Thisisnotabeginner'sairplane!WhiletheFUN-
ONEiseasytobuildandfliesgreat,wemustdiscourageyou
from selectingthiskitas yourfirstR/C airplane.Itishighly
maneuverable,andlacksthe self-recoverycharacteristicsof
agood basic trainersuchasthe Great PlanesPT Series
airplanes.Ontheotherhand,ifyouhavealreadylearnedthe
basics of R/C Flyingandyouare able tosafelyhandlean
"aileron trainer" airplanesuchas the Great PlanesTrainer
Series or BigStickSeries airplanes, the FUN-ONE isan
excellentchoice.
Please inspect allparts carefullybefore startingto
build!Ifanypartsaremissing,brokenordefective,orif
you have any questions aboutbuildingorflyingthis
airplane,pleasecallusat(217)367-2069andwe'llbeglad
tohelp.If youare callingfor replacementparts, please
look up thepart numbersand the kitidentification
number(stampedontheendofthecarton)andhavethem
readywhencalling.
PRECAUTIONS
1.You mustbuildthe plane according to the plansand
instructions. Do not alter or modify the model, asdoing
somayresultinan unsafeor unflyablemodel. In a few
cases the plansand instructionsmaydifferslightlyfrom
the photos. In those instancesyou shouldassumetheplans
and writteninstructionsare correct.
2.You musttake time to build straight,trueand strong.
3.You mustusea proper R/C radio thatis infirstclass
condition,thecorrect ci/.cd engineandcorrect compo-
nents (fueltank,wheels, etc.) throughoutyour building
process.
4.You mustproperlyinstallallR/Candothercomponents
sothat the model operates properly on the ground and in the
air.
5.You musttest theoperation ofthe model before the first
and each successive flightto insurethatallequipmentis
operating,and youmustmakecertainthatthemodel has
remainedstructurallysound.Be suretocheck thenylon
clevisesoften,and replace iftheyshow signsof wear.
6.You mustflythemodel onlywith thecompetenthelpof
awellexperienced R/C pilotifyou are not alreadyan
experienced and knowledgeableR/C pilotat thistime.
Note:We, asthe kitmanufacturer,can provide youwith a
top qualitykitandgreat instructions,butultimatelythe
qualityandfly-abilityof yourfinishedmodeldepends on how
you buildit;therefore,we cannotinanywayguaranteethe
performanceof yourcompleted model,and no representa-
tionsarc expressed or impliedastotheperformanceorsafely
of yourcompleted model.
Remember: Take your timeand follow directions toend
up witha well-builtmodel that isstraight and true.
3

DECISIONS YOU MUST MAKE NOW
ENGINEANDMOUNT SELECTION
Therecommended engine sizerange isas follows:
.25- .40cubicinchdisplacement 2-cycle
.40-.50cubicinch displacement 4-cycle
NOTE:Therearcseveral "High Power" .25 to .34size
engines available whichhave asmuchpower has
some .40size engines yet weighaboutthe same as
most .25 size engines. We highlyrecommend cither
theOSMax.32or theSuper Tigrc G34.The FUN-
ONE can structurallyhandlehot .40size enginesbut
becarefulaboutusingheavyengines. The short tail
momentand swept wingmakes iteasy toend upwith
anose heavy model!
This kitincludesa Great Planes MM19 engine
mountthatfitsmost.20-.34(2-cyclc)engines. Ifyou
prefer, you maypurchasea custom enginemount
made specificallyfor yourengine(check withyour
hobby dealer),oryou may choose to installshock-ab-
sorbing rubber-cushioned mounts.
SELECTION OF WHEELS
Tosaveweight,werecommendusinglightweight
foam rubber wheels.
2-3/4" diameter mainwheels are recommended.
The larger the diameterthemore they willabsorb
hard landingsand thebetter they willrollon grass
fields). Ifyou builditwithtricyclelandinggear, the
nosewheel should be1/4"smaller than the main
wheels.
A1-1/4"diameter tailwheel is recommended.
RADIO INSTALLATION
The FUN-ONEiscapableofusingcomputerra-
diosand otherradioswithmixingfunctionsto pro-
vide flapcrontypecontrol.Thistypeof mixinguses
aseparate servo foreach aileronand allowsboth ai-
leronstomove inrelationto theelevator.The
flapcronswilldrop when upelevatorisapplied,and
vicc-vcrsa, whichenablestheplaneto performvery
tightmaneuversand also enhances its slow flight
capabilities.ThissetupalsoprovidesIhcmost pre-
cise flightcharacteristicssinceThe ailerons are hooked
directly to the servo withthe control horn in the
middle ofthe aileron (very littleslop).
If you have a radiowithoutmixingcapabilities
you willnormallyinstallonlyone servointhe center
ofthe wing.NOTE: Ifyouarcgoingto usea high
power .40size engineyoushouldconsiderusingtwo
aileron servos connected by a Y-harnessto achieve
the precise control offeredbythisset-up.There is
also muchlesschance of aileronflutterwithtwo
servos.
Thereareseveralplacesintheinstructionswhich
alertyoutoperformdifferentstepsdependingonthe
setupyouchoose.Youmightalsoconsiderinstalling
the servo railsand tubesfortwo servos even though
you may not plan on usingtwo servos rightnow.
They do not add muchweightand they will bethere
ifyou ever needthem.
OTHERITEMSREQUIRED
0Four-channelradiowith4 servos(A radiowith atleast
five channels, 5 servos and mixingcapabilities is
required ifflaperons willbeused).
0Propellers (see engine instructions for recommended
sizes).
0Spinner (2" diameter)
0Fuel Tank (6 ounce)
05/32"Wheel Collars (2- for tricycle)
03/32"Wheel Collars (2 - for taildragger
02 RollsMonokote covering (orsimilar)
0Silicone Fuel Tubing (std. size)
0WingSeating Tape(orsilicone sealer...see
instructions)
0Latex Foam Rubber Padding (1/4" thick)
0Dubro "E-Z Connector" (orequivalent)
0Flex-Cable Pushrod for Throttle (& Nosegear)
SUPPLIES ANDTOOLS NEEDED
02 oz. Thin CA Adhesive
02 oz.Medium orThick CA Adhesive
02.5 oz.. 5-MinuteEpoxy
0Hand or Electric Drill
0Drill Bits:1/16", 5/64", 3/32", 7/64",
9/64", 13/64",7/32", and 1/4"
0Sealing Iron
0Heat Gun
0Hobby Saw (Xacto Razor Saw)
0Xacto Knife, #11Blades
0Pliers
0ScrewDrivers
0T-Pins
0Straightedge
0MaskingTape (Requiredfor construction)
0Sandpaper (coarse, medium,finegrit)*
0T-Bar SandingBlock (or similar)
0Waxed Paper
0LightweightBalsaFiller
01/4-20Tap, Tap Wrench
0Vaseline Petroleum Jelly
0Dremel Moto Toolorsimilar (optional)
*NOTE:On our workbench, we have four 11"T-Bar sanders,
equipped with#50, #80, #100 and #150-gritsandpaper.This setup
is all thatis required for almost any sandingtask.We also keep
some #320-grit wet-or-dry sandpaper handy for finish sanding
4before covering.

5

COMMON ABBREVIATIONSUSED IN
THIS BOOK ANDON THE PLANS:
Elev = Elevator
Fuse = Fuselage
LE = Leading Edge (front)
•LG= LandingGear
Lt=Left
Ply = Plywood
RI = Right
Stab= Slabilizer
TE = TrailingEdge (rear)
"=Inches
Tri= Triangle Stock
TAIL FEATHERS
BUILDTHE STABILIZER AND
ELEVATORS
D1.Tape the fuselage plan down to yourflatwork
surface.Tape a pieceof waxedpaperover the staband
elevatorportion of the plan.
D2.Cut the stableading andtrailingedges from the
1/4"x 1/2"x 30"stick (FUN1S01).They can be cut
slightlyoversize since we willsand them tothe correct
length later.
TYPES OF WOOD
GET READYTO BUILD
D1.Unroll the plan sheets.Re-roll the plans inside
out to make them lie flat.
D3.Taper both ends ofthe 1/8"x 1/4"x 14-7/8"
BasswoodStabBrace(FUN1S03) asshownontheplans
and glueitto thefrontedge oftheslab trailingedgewith
CA. Usetheplansasa reference to center thebraceon the
TE.
D2.Remove allpartsfrom the box. As you do, figure
outthe name of each partby comparingitwiththeplans
and the partslistattheback of thisbook. Usinga feltlip
pen, writethepartname or size on each piece to avoid
confusionlater.Use thedie-cutpatterns shownon page 5
toidentifythedie-cutpartsandmarkthembeforepunch-
ing out.Save allscraps.Ifany ofthe die-cut parts are
difficulttopunchout,donotforcethem! Instead,firstcut
around the partswithan Xactoknife.Afterpunchingout
the die-cutparts,use yourT-Bar or sandingblock to
lightly sand the edges toremove any die-cuttingirregu-
larities.
D3.As you identifyand mark theparts, separate them
into groups,suchas fuse (fuselage),wing,fin and stab
(slabilizer),andhardware.
U4. Cut the stab center pieces fromthe1/4"x 1"x
30"stick(FUN1S04)and pinthem inplace ontheplan.
Makethefront"brace"byfirstcuttingittolength,thenset
it ontheplan and drawlines where the cuts willbe.
6

D5.Pintheleadingand trailingedges inplace and
glue everythingtogether withthinCA D8.Lay the 1/8"wireelevatorjoiner(WBNT145)
in place on the elevatorsand markitsoutlineusinga fine
point fell-tip pen. Be sure topositionthe joinerwire
directlyover whereitisshown on theplanswhichgives
you about1/32" clearancebetween thefrontof thewire
and the trailingedge of the stab.
D9.Remove the elevators from theplanand drawa
centerlinealongtheleadingedge ofeach.Accuratelydrill
holes inthe elevatorsforthe1/8"wirejoiner.Beginby
drillinga 1/16" or 5/64"pilothole,thendrillthefinalhole
to a depth of7/8" witha 9/64" drillbit.(The hole isdrilled
slightlyoversize to allow for positioning,and to create a
hard epoxy "sleeve"around the wire).
D6.Cut the "ribs"from the 1/4"square x 30"stick
(FUN1S02)andgluetheminplace. Removethestabfrom
the worksurfaceand applymed/thickCA to allof the
joints.Sand both sides ofthe stabsmooth and replace the
stab on the plan.
D7.Cut the two elevators from the Tapered Elevator
Strip (FUN1S05) and pin or tape them in place behind the
stab.
D10.Usingan Xactoknife,sharpentheinsideof one
end ofa 1/8"diameterbrasstubeand use itto cutgrooves
in the leadingedge ofthe elevators to accept thejoiner
wire.
D11.Roughen the joinerwire withcoarse sandpaper,
thencleanthewirethoroughlywithalcoholtoremoveany
oily residue.

U2.Cut the finand rudder frame from the1/4"x
1/2"andthe 1/4"x 1" slicksandpintheminplaceoverthe
plan. PutadropofthinCAoneachjointbutbecarefulnot
togluethe finto the rudder.
D12.Trialfitthejoinerwire into the elevators, then
glueitinusing5-minuteepoxy.Workplentyofepoxyinto
theholes witha toothpick,thenpintheelevatorsinplace
overtheplantoinsureperfectalignment.Keepthejoiner
pushedintotheelevatorsallthewaytokeep a 1/32" gap
between the frontof thejoinerandtheslab trailingedge.
Keep thisassembly pinned down untilthe gluehas com-
pletely cured.
D13.Remove the stabfrom the work surfaceand sand
the tipsof theleadingand trailingedge flushwiththe stab
ends. Drawa centerlinearoundthestaband sand the
leadingedge and the tipsoftheslab to anice roundedcross
section. D3.Cutthe dorsal finfrom the l/4"xl"slick and tack
glue itto the finusingtheplanto correctlypositionit.The
dorsal finmay haveto be removed later.Cutthe rudder
gusset from the same stick and glueitinplace.
D14.Remove theelevators fromthe planand sand the
leadingedgetoaV-shapeasshownontheplans.Tapethe
elevatorsinplace againstthe slab and sand the elevator
ends to matchthe stab. D4.Cutthe "ribs" fromthe 1/4"square stick and glue
them in place withCA.
BUILDTHEFINANDRUDDER
D1.Tape the fuselage plan down to your flatwork
surface.Tape a piece of waxed paper over the finand
rudder portion ofthe plan.
D5.Remove the finand rudderfromthe work surface
and applymed/thick CA toalljoints.Use a T-bar or
sanding block to sand both sides smooth.
8

I—I 6.Carefullydrawa centerlineallaroundthe edges
ofthefinandrudder(this willhelpto maintainsymmetry
when sanding).
TEMPORARILY INSTALL HINGES
(Do not glue)
NOTE: On an experimental basis, we have included
"laminated hinges" inthiskit,and the followinginstruc-
tionsare writtenfor thistype of hinge.OurR&Ddepart-
menthasthoroughlytestedthesehingesandfoundthemto
beeasy to installand sufficientlystrong and durablefor
this type of airplane. However, asthe kitbuilderyou are
reminded thatyou are ultimatelyresponsiblefor the struc-
turalintegrityof youraircraft.Ifyou arenotconfident
using thistypeofhinge,please feel freeto substituteyour
favorite hinge.
I_I1.Lay therudderand elevatorson theplanand mark
the hinge locations. Place therudderagainstthefinTE
and transferthemarksover to thefin.Place theelevators
againsttheslabTE and transferthemarksoverto theslab.
1—17.Usinga sandingblock and coarse (50 or 80-grit)
sandpaper, sand both sides ofthe rudder to a taperas
shown on the plans.The trailingedge shouldend up
approximately3/32"wideandhavearoundedshape. (Do
not sand to a sharpedge). Sand the bottom edge toa
rounded shape. Sand theleadingedge to a "V-shape" as
shown on theplan.Sand the lop and frontedges ofthe fin
and dorsalfinto a roundedshape butleave thetrailing
edge square.
CAUTION!!!: You mustuse extremecare
whencuttinghingeslots withan Xacto knife,
toavoid cuttingyourself!If thebalsa part
breakswhileyou are pushingon the knife,the
bladecould go intoyourhandbefore you
knowit! A good precautionisto wear leather
gloves whileperformingthefollowingsteps.
D2.Cut the hinge slots onthe accurate centerlines
whichyou previouslydrew,usingan Xacto knife.The
recommended procedurefor cuttinghingeslots withan
Xacto knifeis givenbelow.
A. Begin by carefullycuttinga very shallow
slit inthe trailingedge at the hingelocation.Thisfirst
cutisto establishyourcutinthe rightplace, socon-
centrateon stayingon the centerlineand don't cut
too deep!
B. Makethree or fourmore cutsinthe same
line, goingslightlydeeper each time.As youmake
these additionalcuts,workon going straightintothe
wood. Continuethisprocess while"wiggling" the
knifehandleback and forthuntiltheblade has reached
the proper depth forthehinge.
I_I8.If youarc buildinga taildragger-check the plans
and markthe locationofthe tailgear(WBNT128)on the
rudder.Drilla7/64"holeintherudder(theholeisdrilled
slightlyoversize to allowforpositioning,and to create a
hard epoxy "sleeve" aroundthe wire).Then groove the
rudderleadingedge to accept thetail-gear wire usingthe
sharpened 1/8"brasstubefrom earlier. (Secthephoto at
step 10onpage 7).
9

DC.Trialfitthe hingeinto theslot. If the hingeis
difficulttopushin,re-inserttheknifeandmoveitbackand
forth in the slot a few limesto enlarge the slot.
D2. Position one of the1/8"die-cutbalsa rear fuse
sides (FUN1F02)behindthe frontfusesideyou just
assembled.Slidethetwo parts togetherpressingthem Hard
againstthework surface.Linethetwopartsupover the
planand applythinCA along thejoint.Sand both sidesof
the balsafuseside smooth.
D3.Insert the hinges into the slots and trialfitthe
rudderand elevatorsin place on the finand stab.Do not
gluethehingesuntilyouare instructedto do solaterin
thisbook. Hingegluinginstructionsare included later.
FUSELAGE
CONSTRUCTION
PREPARE FUSE SIDE
NOTE: The photos show both fusesides being as-
sembled at thesame time to helpyou identifythe parts.
You should assemble one side firstasthe instructions
explain. D3.Lay one of the 1/8"die-cut plywoodfront fuse
doublers (FUN1F06)on lop of thebalsafuseside. The
doublershould lineupwiththe fusesideat the front1/2"
ofthedoubler,the rear 3-1/2" of thedoublerand around
the wingsaddle area. Studytheplanand photo carefully
tomakesureyoucorrectlypositionthe doubler.When
you have it in position apply thinCA around alledges of
the doubler, includingthe insidelighteningholes.
D1.Position oneofthe 1/8"die-cut balsa upper
front fuse sides (FUN1F03)above one of the 1/8"die-
cut lower front fuse sides (FUN1F01).Slide the two
parts together pressing them flatagainstthe work surface
and apply thinCA along thejoint.
D4.Glueone ofthe3/32"balsa die-cutrear fuse
doublers (FUN1F05) to the fuse side lining it up with the
back edge of the fuselageand thetop and bottom of the
fuseside. Use thinCA to glueit in place. (The photo for
thisstep is at the top ofthe nextpage).
10

holes. This willautomaticallycenter it.Hold itin place
and use a nailto make a markinthecenter of each hole.
D5.Go back to step 1 and assemble the other fuselage
side. BECAREFULTOASSEMBLEARIGHTAND
ALEFT FUSE SIDE.DO NOT MAKETWO EX-
ACTLYALIKE!!!
D2.Remove theenginemountanddrill9/64"holes at
the bolt locations, then installthe 4-40blind nuts (NUTS001)
ontheBACKof Fl.Press the blindnutsinwithpliers,or
taptheminwitha hammer.
D3.Temporarily attachtheenginemountto the fire-
wallwiththe4-40 x 5/8"bolts (SCRW052). Use thebolts
to helppullthe blindnutsintoplace.Ifyouareusinga
differentmountand more than1/8" of theboltprotrudes
throughthefirewall,youshouldcutofftheexcessboltlength.
4.40 x 5/8"
ASSEMBLE THE FUSELAGE
D1 Lay the twofuselagesides down flaton thework
surfacewiththedoublers facingup. TrialfitformersFl,
F2A, F3, F4A/B,F5 and F6(fromFUN1FO8AND
FUN1F09)inplace on both fusesides.
D6.Glueformer F4B (FUN1F09)onformerF4A
(FUN1F08) liningupthe edgesasshown inthe photo.
PREPARE THE FIREWALL (Fl)
D1.Use a straightedge to drawtwo crossinglines
from corner to corner on the FRONTface of formerFl
(FUN1F20). Refer to the fuseside viewon the plansto
determine the frontof the firewall.Position the engine
mount(MM19D90)againstformerFlsothatthecrossing
lines arc visiblethrough each of the fourenginemount
D2. Using#64 rubberbandstohold everythingto-
gether,assemblethefusesidesalongwiththeformersand
the 1/8"die-cutbalsa rear fuse bottom(FUNF04))and
the 1/8"die-cutplywood front fuse bottom(FUN 1 F09).
11

MakesureeverythingisseatedproperlyandapplythinCA
to allof thejointsstarlingat formerFland workingyour
way to the rear. Atthe rear of thefusegluethetwo sides
together. Do one former/sectionata timeand hold
everythinglightlytogetherwhilethe gluecures. This
structureis self-aligningand can be done rightin yourlap,
itdocsnot need to bedone on a flatsurface. Apply med/
thickCA to allthejoints.
D3.Gluethe1/4"x 2"x 2-5/8"plywood landing
gear plate (FLJN1F13) in place with med/thick CA or
epoxy.Itgoesintheforwardposition behindformerF2
fortaildraggcrsand intherearpositionbehindformerF3
for tricyclegear.OPTIONAL:Ifyouwanttoyoucan cut
an extralandinggear plateandglueone ineach position
and soyou can switchfromone styleof landinggear to the
other.
D6.Cut the 1/8"x 3" x 6-1/2" middle bottom sheet
(FUN1F22) of balsa exactlyinhalf tomake two3-1/4"
pieces and glue them inplace onthe bottom of the fuse.
Note: Thegrain should run ACROSSthefuselage. Sand
theedgesof thesheeting flush withthe fuse sides.
D4. Cutthe1/8"x 1/8"x4"balsaspacer(FUN1F21)
exactlyinhalftoget two2" pieces. Gluethese pieces into
theother landinggearcutout.
D7. Cutpiecesof the1/4"x 30"balsa triangle
(BAL143)to thecorrectlengthand gluetheminplace
aroundthefirewall,alongthefrontfusebottom,alongthe
frontof F2Aandabove thelandinggearplate.The plans
and the photos helpshow whereihe trianglegoes.
D5.Trimthefuselagesides flushwiththespacers you
justglued in.
D8.GlueformerF2B (FUN1F09)inplace on top of
formerF2A.Sand thelop oftheformer flushwiththe top
edgeofthe fuselage.
12

D9.Usingepoxy securelygluethe1/4"plywood
wing bolt block (FUN1F18)inplace.Noticethatthe
blockiscutsquareandthereisa slightgap towardsthe
rear. Simplypress thefuselagesides uptightagainstthe
wingboltblockuntilthegluecures.Addthree pieces of
1/4"triangleunderneaththeblock asshowninthe pholo.
D10.Installtheouterpushrodtubes(PLTB011) by
threadingthemthroughformersF5 and F6and then
throughtheOPPOSITE fuseside.Makesurethe one that
goes through(thehighestholeinF6 isabove the other
where theycross. Allowthemto extendabout1" pastF4B
and 1"past the die-cutfuselageexit.Markwherethetubes
contacttheformers and remove thetubes.Scuffupthe
tubesurfacewith100gritsandpaper in those locationsand
replace inthe fuselage.Gluethetubesinplace withmed/
thick CA.
D12.Ifyouwantto installan antennatubeinthe
fuselage,now is the timetodo that.We normallyuse a
piece of pushrodtubingand secureitalongthefuselage
bottom, exitingnear(the rearof thefuselage.Be sureto
anchor the tubesecurelyas (themaneuversthisplane is
capable of could knock itloose).
D11. Cutthe tubes offflushwiththe fuselageside and
apply some balsafilleraroundthe tube.Afterthefiller
dries sand everythingflushwiththefuselage side. (See
photo for thisstep in nextcolumn)
D13.Securely gluethe3/32"die-cutstab bed
(FUN1 F07) in place withCA. The embossed lineon the
stab bedshouldbe facingup.Makesureitis sealed prop-
erly sothe slab willsitlevel withoutmodification.
13

D14.Center former F4T(FUN1F08)ontop of former
F4A/B. Theback of F4Tshouldbelinedupwiththe back
ofF4Bandit should betiltedback until the top of F4Tis
4-5/8" from F5.Whenpositionedcorrectlyglue it inplace
withmed/thickCA.
D17.Locate the1/16"x 2-5/8" x 16"turtle deck
sheeting (FUN1F16) andcutit intwo as shown inthe
sketch below.
Cuthere
1/4"
2-3/8"
TurtleDeck Sheeting
D15.Noticean embossed lineacross the slab bed
3-7/8"from therear. This is where thefrontofthestabwill
be.If itis hard to seedraw a linethere.
D18.Gluethesheetingontothelittleledge formed by
the fuselageside andthebottomstringer.
D16.Gluethree 1/8"x 3/16" x 18"balsa stringers
(FUN1F14) inplace as shown in the photo. The bottom
stringershouldstartatthelineyou justdrew on the stab
bedand remain1/16" awayfromthe edge ofthefuselage
side to allow for the turtledeck sheetingwhichwillbe
appliedlater.The top stringershouldbeattachedto the
bottom stingernear the stabbedbutnot betouchingthe
stabbedas shown inthephoto. Themiddlestringershould
startat former F6.Cutthe excess stringersoffflushwith
former F4T.Do the same for the other side ofthe turtle
deck.
14
D19.Use a damp rag to wet the outsideof the turtle
deck sheetingto makeitbend easier.Applysome med/
thickCA toformersF4T, F5 and F6and bendthesheeting
intoplace. Use at leastfourstripsof maskingtapetohold
the sheeting.ApplythinCA alongthestringersand allow
the glueto cure. Gluethe other piece of sheetingin place.

D20. CutthesheetingoffflushwithformerF4T andthe
end of thestringersandusea sandingblockto sand thetop
ofthe sheeting flushwiththe top of the formersand
stringers.Be careful not sand any dipsorvalleysintoit
orthe top willnot fitnicely.
D23. Gluethe 3/32"die-cut turtle deckface(FUN 1 F07)
inplace on thefrontof F4Tandsanditflushusinga
sandingblock pressed flatagainsttheturtledeck.Do not
roundoffthecornersof theface becausethecanopywill
bullupagainstthispiece. Also sand itflushwiththe face
ofF4B.
D21.Gluethe3/16" x 1-3/8"x 14-7/8"balsa turtle
deck top (FUN1 Fl5) inplacemakingsureitiscentered.
Cutoffthe ends and sandthem flushwithformerF4T and
theend ofthe stringers.
D24. Gluethe3/16" x 15/16" x 3"balsa hatch front
(FUN1F11)in place. Allowitto overlapformerFl
slightly(1/32" or less). Sand itflushwiththe fusesides
and the frontofFl.
D22. Use a razorplaneto carefully"rough" carve the
turtledeck top and thensand itwitha sandingblock to
blend in withthe sheeting.
D25. Gluethe1/4"squarex 2-5/8" basswood hatch
holddownblock (FUN1 Fl7) tothefrontof formerF2B.
Noticethatthetop of thehold down isslantedandnot
flushwiththe top of thefusesides.
15

D26.Gluethe1/16" x 1" x 1" plywood hatch tongue
(FUN1F12)tothe frontof the hatch (FUN1F10)sothat
halfof the tongue extendspast the edge of the hatch.
to roundoffthe back edge of thehatchbecause the wing
fairingwillbullupagainstthissurface.
#2 x 3/8"
Sheet Metal Screw
#4 FlatWasher
WING ASSEMBLY
NOTE: The followinginstructionsexplainhowtobuild
the wingon a flatsurfaceusingthebuiltin"JigTabs",
directlyon the plans.
D27.Positionthe hatchon the fuselageand use a piece
ofmaskingtapeto holditagainstthe hatchfrontand act
likea hinge.PushaT-pinthroughthehatchapproximately
3/8"from theedge of the fuselageand 1/16" infrontof
F2B. Pick thehatchupslightlyand look seewhere the
pin stuckintothebasswood hold down.Itshouldenterthe
basswood as close to theformeras possible (within1/32").
If itdoes not,adjustthepositionof the pinand tryitagain.
Do this on both sides of the hatchand then drilla 1/16" hole
where each pin is.
D28.Remove the hatch and enlarge the holes in the
hatch only 3/32".
D29.Usetwo #2x 3/8"sheetmetalscrews (SCRW024)
and two#4washers (WSHR005)to screw thehatchinto
place. Sand the sides and back of thehatchflushwiththe
fuselage sides and the face offormer F2B. Be carefulnot
BUILDTHE WINGPANELS
NOTE: It willbe helpfultobuildthewingon a piece of
"Celotex" or other semi-soft(and flat) surface,into
whichyou may easilyslickpinsfirmlyholddown the
wingpartswhilebuilding,avoidwarps.*Available
from lumbercompanies and home centers.
D 1. Tape theplan to your flat work surface, and cover
the wingdrawingwithwaxedpaper(so youwon'tgluethe
wingtheplan!).NOTE: Ifyourworkspace islimited,
you may cutthe leftand rightwinghalfdrawingsapart.
D2.Theshaped wing leading edges (LE) (FUN1W07)
and trailingedges (TE) (FUN1W08)arefastenedto-
getherby thinstripsof balsa.Separatethem by cutting
betweenthetwopieces. Sand awaytheexcess balsathat
remainsalong theedges aftercuttingthem apart,usinga
T-bar with100-grit sandpaper.
D3.Before usingthe1/4"x 3/8"x 28"hard balsa
spars (FUN1W09),examinethemcarefullyforpossible
imperfections.Look for knots,soft spots, diagonalgrain
16

and anyother imperfections.Ifpossible, positioneach
spar sothe imperfections(ifany)are on theouterhalfof
thewingpanel(towardthetip),wheretheywillbeleast
affectedby highstress.Ifthesparsarc warpedslightly,try
to "balancethemout"by installingthewarped spars in
oppositedirections(see sketch).NOTICE:Ifyou feel
thatanyofthewingpartsarcunusableduetoseverewarps
orotherdefects,giveusa calland we'llreplacetheparts.
TWOWARPEDSPARSINSTALLED
THIS WAYWILLRESULTINA
STRAIGHTWING
TWOWARPEDSPARSINSTALLED
THIS WAYWILLRESULTINA
WARPEDWING
D4. Find ihefour1/8"x 3/8"x 14" balsa spar
doublers (FUN 1 W 17). Sand the last2"oneend of each
spardoublertoataperasshowninthephoto. Gluethespar
doublerstothesparswiththesquareend of the spar
doublerlinedupwiththespar end.Sand thedoubler to
matchthe spar and to remove anyexcess glue.
NOTE: Follow steps 6 through 13 to build the
LEFT wing panel, then repeat these steps to build
the RIGHT wing panel.
Work Surface
DD 6.Use some scrap pieces of1/16" balsa to shimthe
sparupofftheworksurface1/16". Placea"shim" inevery
other ribbay andpina spar to theplanwiththe spar
doubler up and toward the root.NOTE: The spars are
cutslightlytoo long. Positionthe spar on the plansoap-
proximately1/8"extendspast thecenterofthe wingplan.
DD 7.Place the ribson the spar withthejigtabs down,
in theirapproximateposition,butdo not glue.NOTE:
The wingis builtupside down.
D5.Carefullypunchoutallthe die-cut3/32"balsa
wingribs.Sand theedges slightlytoremove anydie-
cuttingirregularities.Ifyou are goingtobuildthe wingon
awingjigdo notpunchoutthelightningholes yetas some
ofthemcontainthejig holes.Youmayeven haveto tack
gluetheseinplaceuntilthe wingisremoved from the jig.
If you arcgoingto installindividualservos for each
aileron,cutoutme servorailnotches inribsW4 and W5.
NOTE:Ifyouare goingtouseonlyone servo now but
thinkyoumaywanttohaveindividualservos later,go
ahead andbuildthe servo railsintothe wingand cover
over them.Then they willbethere ifyou decide you want
them. 17
DD 8.Examinethe shaped, notched balsatrailing
edges. Noticethatthenotchesat one end of each TE arc
closer together. Thisis the"root" end ofmeTE. Insertall
ribs intotheTE notches. TheTE shouldrest on the ledges
onribsW3,W6andW10butmakesurethatitisalsoflush
withthetopsofallribs. Check to makesurethateach rib
isperpendicularto the work surfaceand apply a drop of
thin CA to each jointon the TE and thespar.
NOTE: ThinCAgluemaybeused intight-fittingjoints,
buttoinsurestrongjointswe recommend thatyou follow
upby also applying medium ormed/thick CA to alljoints.
17

DD 9.(Glue thetopspar inplace withthe spar doubler
facingdown. Glue the LEinplacemaking sure it is resting
properly inthe jiglabsand it is centered "UP and DOWN"
ontheribs. It may benecessarytoremove a smallamount
of materialfrom thejiglabs fortheLEto fitproperly.
IMPORTANT: In the following steps you'll find it
necessary toremove some of the pins holding thewing
downto your buildingboard. Asyou do,take other steps
as necessary to continueholding the wing down, such as
byapplying weight lothetop ofthewing,orbyrelocating
thepins.
NOTE: Therewillbeasmallgapbetweentheribsandthe
webs but thisis normal.
DD 12. Withthewingaccuratelylined upover the
plan, cuttheleading edge. trailingedge and thesparsoff
at therootend.Use a draftingtriangle orsquare toaccu-
rately transfer the cutofflines from the plan tothe struc-
ture.
DD 13. Cut theLE.TE and Spars offflush withrib
W10. Ifyou built thewing ona wingjig, now is thetime
to remove the panel from thejig.
D14.Goback tostep 6 and assemble the other wing
panel.
DD 10.Position the 3/32" x 3"x 14-7/8"balsa shear
web sheet (FUN1W14) over theshear web templateon
the plan.Make sure the sheet is correctlyaligned withthe
template and transfer themarks from the plantothesheet.
Movethe sheetovertothesideandwriteeach web
designation onto the sheet so you will know where each
onegoes. Use a straightedge andanXactoknife to cut
between the linesmakingthe shearwebs.
JOINTHEWINGPANELS
D1.Ona flatsurfacetrialfitthetwowing halves
together. The leading edges, trailingedges and thespars
should bullupnicely against each other. Sight down the
trailingedges to make suretheyare straightwitheach
other (No sweep inthewing). Sand whereneeded to
achieve a goodstraightfitbetween the wings. NOTE:The
dihedral is automaticallybuiltintothewing bybuilding it
flat upside down on thebuilding board. This makes the lop
spars level with each other andthe bottom spars will rise
slightlywith thetaperof the wing.
DD 11.Securely glue thewebs to thebacksideof the
spars.Centerthewebs between the spars andthe ribs.D2.Use med/thick CA to "tackglue the twopanels
togetherandpinorholdeverything inplace whiletheglue
18

cures. Make surethe sparsare precisely lined up with
eachother.
trailingedges. The topof thedowel alignershouldheflush
withthetop ofthe trailingedges. Sand orfile a round
notchineachtrailingedgewherethedowelalignernotches
areasshown inthephoto.
D3.Trialfitthe1/8"plywood wingjoiner(FUN1 Wl 3)
inplace betweenthe spars. It should fitbetween thespars
without protruding past the edges of thespars.Sand it if
neededto achievea good fitwithoutpushing the spars
apart. Securelyglue it inplace withepoxybut becareful
notto getanyglueonthe front orback of thespars.
D4.Trialfit the1/32"plywood dihedral braces
(FUN1W06) inplace. They easilyshould fitbetween the
ribs andshould not extendpast theouteredges ofthe spars.
Hold orclamp them tightly against the spar while gluing
theminplace with epoxy.
D6.Glue two1/8"die-cutbalsaW1C ribs
(FLIN1W02) together making sure they arelinedupwith
each other.
D5.Glue the1/8"plywood die-cut dowel aligner
(FUN1FOS) tothe back of thetrailingedge (Ifyou are
goingtouseoneaileronservojust tackgluethealigner
inplace as itwillbe removed later). Position it so the
embossedlineiscentered with mejoint between thetwo
D7.Gluea 1/8"plydie-cut W 1 B rib(FUN1 WO 1)to
onesideofthe W 1 C ribs and glue a 1/8"plydie-cut W ID
rib(FUN1W01) to the other side of the W 1 C ribs. Line
theseribs upso thatall oftheirtrailingedgesareeven and
sand off the extrabalsaaroundthedowelholeflushwith
19

the plywood ribs. NOTE: when makingthisribassembly
for the otherwing,besure to gluethe plywood ribsto the
opposite sides of the W1C ribssoyou willhavea "right"
and a "left" asthephoto above shows.
D8.Roundoffboth ends ofeach 1/4"x 5-3/4"dowel
(DOWEL037) andtrialfitthemintothe Wlribassem-
blies. Gluethedowels inplace withplenty of med/thick
CA orepoxy.
D9.Position the wingback over theplanand trialfit
both Wlribassemblies. Enlarge the notches inthe TE if
needed to get thedowels to bepositioned exactly over the
notches inthedowel aligner.Tackgluethe ribassemblies
atthetrailingedgesotheyarecenteredupanddownon the
trailingedge. Don'tworryifthedowels are not seated in
thealignernotchesbutdomake surethey arebothdirectly
above thealignernotches. Securely gluethe frontof the
ribassembliestothedihedralbrace. Addsomemed/thick
CAtothetrailingedgejointbutdon'tallowexcessglueto
accumulateon the trailingedge or the 1/16" sheetingwill
not fitwell.
D10.Add a piece of 1/4"triangle(BAL143)to each
outside spar/Wlribjointand a smallpiece at the trailing
edge ofeach ribassembly (Seephoto atstep 11).
D11.Gluethetwo1/8"plyW1Aribs (FUN1W01)
togetherand gluetheminplaceinthecenterof thewingas
shown in the photo. Gluea piece of 1/4"triangleon both
sides of the ribsnear the spars.
D12. Gluethe 1/8"balsa W2B ribs (FUN1W02) in
placeintheremainingnotches.Besurethe1/2"diameter
hole is down.
D13.Remove the wingfrom theworksurfaceand test
fititto the fuselage.Sand a "Flat"on thefrontof the
leadingedge toallowitto seal properly.The bottomofthe
leadingedge will still keep the wing from seating all the
wayinthesaddlebutwecanmakesurethewingisaligned.
D14.Tie a 3'piece of stringto a T-pin and sticktheT-
pinintothe middleof theslabbase attheveryback.Pull
the stringouttoone wingtipandmarkitor gripitwithyour
fingerswhereittouchesthetip.Swingthestringover to
the othertipto seeifthe twodistancesare equal.Ifthey
are, makea markon theleadingedge and formerF2B so
you willknowwhenthewingison correctly.Ifthe
distanceis not equal,adjustthe winguntilitis, then make
the mark.
Bothdistancesmust
be equal!
20