GREAT PLANES Ultimate 40 User manual

WARRANTY
GreatPlanesModelManufacturingCo.guaranteesthiskittobe freefromdefectsin bothmaterialand
workmanshipat thedate of purchase.Thiswarrantydoes not 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 finalassembly or material used forfinal assembly, noliability shall be
assumed nor accepted forany damage resulting fromthe use by the user of the finaluser-assembled product.Bythe
act of using the user-assembled product, the user accepts all resulting liability.
Ifthe buyerisnotprepared to accept the liability associated with the useof this product, the buyer isadvised
to return this kit immediately innew and unusedcondition to the place of purchase.
While this kithasbeen flight tested to exceed normal use, ifthe plane will beused forextremely highstress flying, such
as racing, the modeler isresponsible fortaking steps to reinforce the high stress points.
READTHROUGH THIS MANUALBEFORE
STARTINGCONSTRUCTION. IT CONTAINS
IMPORTANT WARNINGS AND INSTRUCTIONS
CONCERNING THE ASSEMBLY AND USE OF
THISMODEL.
P.O.Box788Urbana, IL61803 [phone]
©Copyright 1998ULT4P03V1 1

Introduction ......................................................................3
Precautions.......................................................................3
Decisions You Must Make................................................3
Engine Selection .........................................................3
Preparations .....................................................................3
Required Accessories..................................................3
BuildingSupplies and Tools.........................................4
Optional Supplies andTools ........................................4
Types of Wood .......................................................4
Common Abbreviations................................................4
BuildingNotes..............................................................5
Get Ready to Build.......................................................5
Inch/MetricRuler..........................................................5
Die-Cut Patterns......................................................6&7
Buildthe TailSurfaces.....................................................8
Build the Stabilizer .......................................................8
Build the Elevator.........................................................8
Build the Fin. . ............................................................9
Buildthe Rudder..........................................................9
Hingethe TailSurfaces..............................................10
Finish the TailSurfaces..............................................10
Fitthe Torque Rods ...................................................11
Install Tailwheel Bracket on Rudder...........................11
Buildthe Bottom Wing...................................................12
Wing Preassembly.....................................................12
Buildthe Wing.. . . . ...............................................12
Sheet the Topof the Wing..........................................14
Sheet the Bottom of the Wing....................................15
Complete the Bottom Wing........................................16
Build the Ailerons .......................................................17
Build the Fuselage .........................................................18
Fuselage Preassembly.. ...........................................18
Assemble the Fuselage Sides...................................19
Install the Formers .....................................................20
Mount the Wing on the Fuselage...............................22
Installthe Stabilizer and Fin.....................................23
Assemble the Turtledeck............................................24
Buildthe Top Deck.....................................................25
Buildthe Top Wing.........................................................27
Wing Preassembly.....................................................27
Build the Wing ... .... ..............................................27
Sheet the Topof the Wing..........................................30
Install the Aft Root Ribs..............................................30
Finish Sheeting the Top of the Wing ..........................31
Sheet the Bottom of the Wing.. .................................31
Complete the Bottom of the Wing ..............................32
Build the Ailerons .......................................................33
Engine Installation .........................................................33
Assemble the Plastic Parts ...........................................34
Assemble the Wheel Pants........................................34
Assemble the Cowl ...................................................36
Balance the ModelLaterally..........................................37
Covering.......................................................................37
Prepare the Surface..................................................37
Covering Technique...................................................37
Suggested Covering Sequence................................38
Painting........................................................................38
Final Hookups and Checks ...........................................38
Install the Hinges .......................................................38
Installthe Hardware...................................................39
Attach the Canopy .....................................................39
Radio Installation ...........................................................40
Install the Rudder, Elevator andThrottle Servo .........40
Install the Aileron Servo .............................................42
Check the Wing Incidence.............................................43
Set the Control Throws.................................................43
Balance Your Model .......................................................44
Preflight...........................................................................44
Charge the Batteries..................................................44
Balance the Propeller.................................................45
Find a Safe Place to Fly.............................................45
Ground Check the Model ...........................................45
Range Check Your Radio...........................................45
Engine Safety Precautions........................................45
AMA Safety Code............................................................46
General.....................................................................46
Radio Control............................................................46
Flying...............................................................................46
Takeoff.......................................................................47
Flight.........................................................................47
Landing.....................................................................47
Flight Log...................................................................47
2-View Drawing ...............................................Back Cover
Your Ultimate 40 isnota toy, butrather a sophisticated,
workingmodel that functionsverymuch like a fullsize
airplaneBecauseofitsrealisticperformance,the
Ultimate40, ifnot assembledand operatedcorrectly,
could possibly cause injury to yourselfor spectators and
damage property.
Ifthis isyour firstbiplane model, we recommend that you
get helpfroman experienced, knowledgeable modeler with
your firstflights. You'll learn fasterand avoid risking your
model before you're ready to take the controls for yourself.
For informationon flyingclubs inyour area,you can
contact the national Academy of Model Aeronautics (AMA),
whichhas more than2,500 charteredclubsacrossthe
countryContactAMAat the address or toll-freephone
number below:
Academy of ModelAeronautics
5151 East Memorial Drive
Muncie, IN47302-9252
Tele [phone]
Fax [phone]
Orviatheinternetat:http://www.modelaircraft.org
2

The Great Planes Ultimate 40 isa high performance,
propeller-drivensport biplane that closely resembles the
fullsizeUltimateThe Ultimate40 is verystableand
forgiving,allowing even intermediate skill level pilots to
enjoy it
Thisisnota beginner's airplane! While the Ultimate 40
iseasy to build and fliesgreat, we must discourage you
fromselecting this kitas your first R/C airplane Itlacks the
self-recovery characteristics of good basic trainers such as
the Great Planes PT"Series Onthe other hand,ifyou
have already learned the basics of R/C flying, and you are
able to safelyhandle a 40-sizelow wingairplane, the
Ultimate 40 isanexcellent choice to try your skills atflying
abiplane.
Remember: Take your time and follow directions to end
upwitha well-built model that is straight and true.
Pleaseinspectallparts carefully before starting to build!
Ifany parts are missing, broken or defective, or ifyou
haveanyquestionsaboutbuildingor flyingthis
airplane, please call us at [phone]. If you are
calling for replacement parts, pleasereference the part
numbersandthekitidentificationnumber(stamped on
the endof the carton) andhave them ready when calling.
1Youmustassemblethemodelaccordingtothe
instructions Donot alter or modify the model, as doing so
may result inanunsafe or unflyable model Ina fewcases
the instructions may differ slightly fromthe photos Inthose
instancestheplans and writteninstructionsshould be
considered as correct.
2Taketime to buildstraight, true andstrong
3UseanR/C radiosystem that isinfirst-class condition,
and a correctlysized engine and components (fuel tank,
wheels, etc ) throughout your buildingprocess.
4.You must properly install allR/C andother components
so that the modeloperates properly on the ground andin
the air.
5You must test the operation of the model before every
flight to insure that all equipment isoperating, and you must
make certainthatthemodel has remainedstructurally
sound Besure to check clevises or other connectors often
andreplacethemifthey show signsof wear orfatigue.
NOTE We, as the kit manufacturer, can provide you
with a top quality kitandgreat instructions, butultimately
the quality of your finished model depends on how you
build it, therefore,we cannotin any wayguarantee
the performanceof yourcompletedmodel,and no
representationsareexpressedor implied as to the
performance or safetyof your completed model.
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.
DFour-channel radiowith four servos
DEngine - SeeEngineSelection above
DPropeller (Top Flite Power Point"), Refer to your
engine's instructions forproper size
DFueltank 10oz (GPMQ4104)
DMedium fuel tubing (GPMQ4131)
D2-1/4" Mainwheels (GPMQ4222)
D1"Tailwheel(GPMQ4241)
DTopFliteMonoKote (Approximately 3 rolls)
DPilotfigure (Williams Bros #185)
D1/4" Latex foam rubber padding(HCAQ1000)
DSwitch andcharge jack (GPMM1000)
DTopFlite LustreKote"Paint - SeePainting(page37)
D1/16" Wing seating tape (GPMQ4422)
D6"Servo extension
D2-1/2" White spinner (GPMQ4520)
DFuelfill valve (GPMQ4160)
3

Thesearethebuildingtoolsthatare required.We
recommend Great Planes Pro" CA and Epoxy glue.
D2 oz. ProCA (Thin, GPMR6003)
D2 oz Pro CA+ (Medium, GPMR6009)
D1 oz Pro CA- (Thick, GPMR6014)
D6-Minute Pro Epoxy (GPMR6045)
D30-Minute Pro Epoxy (GPMR6047)
DHand or electric drill
DSealing iron (TOPR2100)
DHeatgun (TOPR2000)
DHobby saw
DHobby knife, #11 Blades
DRazor plane (Master Airscrew®)
DPliers (Common andNeedle Nose)
DScrewdrivers (Phillips and flat tip)
DT-pins (HCAR5150)
D60" Retractable Tape Measure (HCAR0478)
DStraightedge with scale
DMasking tape (TOPR8018)
DSandpaper (coarse, medium, fine grit)
DEasy-Touch" BarSander (orsimilar)
DPlan Protector (GPMR6167)
DLightweight balsa fillersuch as Hobbico^HobbyLite"
(Hobbico HCAR3400)
D1/4-20 Tapand Drill (GPMR8105)
DIsopropyI rubbing alcohol (70%)
DWhite body putty (Squadron SQUR1500)
DBallpoint pen
D90° Buildingsquare (HCAR0480)
DMicro balloons (TOPR1090)
DCanopy glue
DDrill bits 1/16", 5/64", 3/32", 7/64",1/8",9/64",5/32",
3/16", 13/64",1/4",5/16", 3/8"
DBuilderstriangleset (HCAR0480)
Customsandingblockscan bemadefrom balsaorhardwood
blocksanddowels for sandingdifficult to reachspots
Balsa Basswood Plywood
DCA Applicator Tips (HCAR3780)
DEpoxy brushes (GPMR8060)
DEpoxy mixing sticks (GPMR8055)
DCA Debonder (GPMR6039)
DHotSock "(TOPR2175)
DSingle-edge razor blades (HCAR0312)
DCurved tip canopy scissors for trimming plasticparts
(HCAR0667)
D4 oz Pro Wood Glue(GPMR6161)
Elev= Elevator
LE= Leading Edge(front)
Ply = Plywood
TE = TrailingEdge(rear)
Fuse= Fuselage
LG= LandingGear
Stab= Stabilizer
"= Inches
4

There are two types of screws used inthis kit.
Sheet metal screws are designated bya number anda
length.Forexample #6 x 3/4"
D1.Unroll the plansheets Reroll the plansheets inside
out to make them lieflatPlace wax paper or Great Planes
Plan Protector over the planto prevent glue fromsticking to
theplan.
Machinescrews are designated bya number,threads per
inchand a length. Forexample 4-40 x 3/4"
When you see the term "test fit"inthe instructions, it
means you should firstposition the parton the assembly
without using any glue and then slightly modify orsand
the partasnecessary forthe bestfit
Whenever the instructions tell you to gluepieces together,
CA or epoxy may beused When a specific type of glue is
required, the instructions will state the type of glue that is
highly recommended. When 30-minute epoxy isspecified,
itishighly recommended that you use only 30-minute (or
slower)epoxybecause you willneed either the working
time orthe additional strength.
D2 Remove allparts from the box As you do, determine
the name of each partbycomparing itwith the plan and
the parts list included withthiskitUsinga felt-tipor
ballpointpen,lightly write the part name or size on each
piece to avoid confusionlater Use the die-cutpatterns
shown on pages 6 and7 to identify the die-cut parts and
mark them before removing them fromthe sheet Save all
scraps Ifany of the die-cut parts are difficult to remove, do
not forcethem'Instead, cut around the parts Use your
Easy-Touch Bar Sander or sanding block to lightly sand
the edges to remove any die-cutting irregularities.
D3.As you identify andmark the parts, separate them
into groups,such as fuse (fuselage),wing,fin,stab
(stabilizer) and hardware Resealable food storage bags
arehandytostorepartsin as yousort,identifyand
separate them intosubassemblies.
Several times duringconstruction we refer to the "top"or
"bottom' of the model or a partof the model For example,
during wing construction we 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 upandwill bereferredto as the "top"
even if the model isbeing worked on upside-down (ie the
"top" mainspar isalways the 'top" mainspar,even when
the wing isbeing built upside-down).
InchScale
MetricScale
5

6

7

Glue together the pairs of die-cut 1/8" balsa stabilizer
centerS-1,finbottomS-2,rudder bottomR-3 and
ruddertipR-4 to make1/4" thickparts.
D3 Remove the stab fromyour building board Inspect all
theglue jointsand add CA to any jointsthatdon't look
strong Sand the LEand TE flush Sand the entire top and
bottom surfaces of the stab until they are flat and even Be
careful that you don't sand any area of the stab too thin.
D1 Pinthe die-cut 1/4" balsa stabilizer center S-1 over
thestabilizerplanCutthestabouterframefroma
1/4"x 1/2" x 36" balsa stick, allowing approximately 1/16"
extra atthe jointsThe jointswillbesanded flush after the
stab isremoved fromthe building board Glue the outer
frame and stab center together andpinitinposition over
the plan Use theplans or a straightedgeas a guide to
makesurethe stabTE isstraightasyou glueitinposition.
Note: Refrain fromusing excessive accelerator Hours
after it's sprayed on residual accelerator can prematurely
andunexpectedly cure the CA you use later, on nearby
glue joints Unless you must handle or remove the part
fromyourbuilding board rightaway, werecommend
using noaccelerator atall.
D2 Make the 1/8" stab ribs froma 1/8"x 1/4"x 36"balsa
stick.Gluethe ribsinposition.
Hint:Use a sharp, single-edgerazor blade to cut the
stab ribs.
DD 1 Cut a 1/4" x 1/2" x 36" balsa stick to make the
elevator LEandTE Pin the LEandTE inposition over the
plan Allow the LEto extend 1/16" past the root andthe TE
to extend 1/16" past the tip.
DD 2. Cut the rootand tip framefromtheremaining
1/4"x 1/2"x 36" balsa stick Glueandpinthe elevator in
position over the plan.
DD 3 Cut gussets from a 1/4"x 1/2"x 36"balsastick
andglue them inplace
DD 4 Make the 1/8"elevator ribs from a 1/8"x 1/4"x
36"balsastick andgluethem inplace
8

D3.Remove the fin from your buildingboard.Inspectall
the glue jointsand add CAtoany jointsthatdon'tlook
strong. Sand the jointsflush and the entiretop and bottom
surfaces of the finflatandeven. Becareful that you don't
sand any area too thin.
DD 5. Remove the elevatorfromyourbuilding board.
Inspect all theglue jointsand addCA to any jointsthat
don't look strong. Sand the LE,TE, root and tip flush.Sand
the entire top and bottom surface of the elevator flatand
even. Becareful that you don't sand any area too thin.
D6.Go back to step 1 and build the second elevator
following the same procedure.
D1.Pin the die-cut 1/4" balsa rudder bottom R-3 and
ruddertip R-4 over the rudderplan. Cut the rudder outer
framefroma 1/4" x 1/2" x 36" balsastick,allowing
approximately1/16"extraat thejoints.Glue theouter
frame, rudder bottom and rudder tip together and pinitin
position over the plan.Use the plans or a straightedge as a
guide to make sure the rudder LEisstraight as you glue
itinposition.
D1.Pinthe die-cut 1/4" balsa finbottom S-2 over the fin
plan.Cut the fin outer frame from a 1/4"x 1/2"x 36"balsa
stick, allowing approximately 1/16" extra atthe joints. Glue
theouterframeand finbottomtogetherand pinitin
positionover the plan.Use the plans or a straightedge as a
guide to make sure the fin TE isstraight asyou glueitin
position.
D2. Cut the toptwofinribsfromtheremaining
1/8" x 1/4" x 36" balsa stick.Cut thebottomrib froma
1/4"x 1/2"x 36"balsastick. Gluethe fin ribsto the fin LE
and TE.
D2. Cut the rudder ribs and diagonal braces fromthe
remaining 1/8"x 1/4"x 36"balsastick. Glue the ribsand
braces inposition.
D3.Cut the remaining 1/4" x 1/2" x 36" balsa stick to
makethe LEgusset. Gluethe gusset inposition.
D4. Remove the rudder fromyour building board. Inspect
allthe glue jointsand addCA to any jointsthat don't look
strong. Sand the jointsflush and the entire top andbottom
surfaceof the rudder flatand even. Becareful that you
don'tsandanyarea too thin.
9

D1.Placethe stab andelevators over their locationson
the planandlightly mark the hinge locations on the TE of
the stab andLEof the elevators.
D2.Mark the centerline of the hingeson the stab's TE
andelevator's LEusingthe following centerline method.
D4.Cutthehingesfor the elevators andrudderfrom the
supplied 2" x 9" hinge material. Use the hinge drawing
on thefuseplan as a guide.Trimoffthecornersand
temporarily join the elevators to the stabs with the hinges,
adjusting any hinge slots ifnecessary. Donotglueinthe
hingesuntilyou are instructed to doso.
D5.Return to step 1 and use the same procedure to
hingethe rudder andfin.
HOW TO MARK A CENTERLINE
It'simportant that the hingesarecentered andparallelto
the part you are hinging. The best waytostart isby
accurately marking the hingecenterline.
D1.Refer to the Expert Tipthat follows and shape the LE
of the elevators and rudder to a "V" shapeas shown on
the plans.
A. Laythe stab anda ballpoint pen on a flatsurface.
Marka "test line"onthe trailing edge of the stab.
B.Flipthe stab over andmarkanother lineinthe same
location as the first.Ifyou see only one line, then itis
on center. Proceed and mark the centerline ateach
hingelocation. Ifyou see two lines, use playing cards
or business cards to adjust the height of the penuntil
you canmarkthe centerline.
C.Use the same technique to mark the centerline along
the entire length of both elevators.
HOW TOBEVEL THE LEADING EDGE
A. Place the leadingedge of one of the elevators on your
work surfaceand use your ballpoint pen to mark a
"bevel to" line on both sides about 1/8" high.
D3.Cutthe hingeslots inthe elevator and stab using a
#11 blade. Begin by carefully cutting a very shallow slit at
the hinge location to accurately establish the hinge slot.
Make three or fourmore cuts, going a little deeper each
time. As you cut, slide the knifefromside to side until the
slot hasreached the proper depth andwidth forthe hinge.
B.Usingthe bevelto linesandthecenterlineas a guide,
make the "V" on the leadingedge of the elevators with
arazor plane or your barsander.
D2.Use the same procedure to bevel the leadingedge of
therudder.
10