GREAT PLANES Yak-55M Performance Series User manual

INSTRUCTION
MANUAL
Champaign, Illinois
[phone], Ext 5
airsuppor[email protected]
Entire Contents © 2010 GPMA1230 Mnl
READ THROUGH THIS MANUAL BEFORE STARTING CONSTRUCTION. IT CONTAINS IMPORTANT
INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.
WARRANTY
SPECIFICATIONS
Great Planes®Model Manufacturing Co. guarantees this kit to
be free from defects in both material and workmanship at the
date of purchase. This warranty does not cover any component
parts damaged by use or modification. In no case shall Great
Planes’ liability exceed the original cost of the purchased kit.
Further, Great Planes reserves the right to change or modify this
warranty without notice.
In that Great Planes has no control over the final assembly or
material used for final assembly, no liability shall be assumed nor
accepted for any damage resulting from the use by the user of
the final user-assembled product. By the act of using the
user-assembled product, the user accepts all resulting liability.
If the buyer is not prepared to accept the liability associated
with the use of this product, the buyer is advised to return
this kit immediately in new and unused condition to the
place of purchase.
To make a warranty claim send the defective part or item to
Hobby Services at the address below:
Hobby Services
3002 N. Apollo Dr. Suite 1
Champaign IL 61822 USA
Include a letter stating your name, return shipping address, as
much contact information as possible (daytime telephone
number, fax number, e-mail address), a detailed description of
the problem and a photocopy of the purchase receipt. Upon
receipt of the package the problem will be evaluated as quickly
as possible.
Wingspan: 88 in [2235mm]
Wing Area: 1473 in 2 [95 dm2]
Wing Loading: 28−31 oz/ft2 [85−95 g/dm2]
Length: 82.5 in [2095mm]
Weight: 18−19.5 lb [8160−8840 g]
Radio: 5 channel minimum / 9 channel or greater preferred
Engine: 50-55cu in [3.0 – 3.4cc]
two-stroke gasoline engine

2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Academy of Model Aeronautics . . . . . . . . . . . . . . . . . .2
International Miniature Aircraft Assoc. . . . . . . . . . . . . .2
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . .3
DECISIONSYOU MUST MAKE. . . . . . . . . . . . . . . . . . . . .3
Radio Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Radio Recommendations. . . . . . . . . . . . . . . . . . . . . . .3
Servo Recommendations. . . . . . . . . . . . . . . . . . . . . . .3
Battery Recommendations. . . . . . . . . . . . . . . . . . . . . .3
Engine Recommendations. . . . . . . . . . . . . . . . . . . . . .3
Muffler Recommendations . . . . . . . . . . . . . . . . . . . . . .4
ADDITIONAL ITEMS REQUIRED . . . . . . . . . . . . . . . . . . .4
Required Hardware & Accessories . . . . . . . . . . . . . . .4
Optional Supplies & Tools . . . . . . . . . . . . . . . . . . . . . .4
IMPORTANT BUILDING NOTES. . . . . . . . . . . . . . . . . . . .4
KIT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
KIT CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ORDERING REPLACEMENT PARTS. . . . . . . . . . . . . . . .6
PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ASSEMBLETHE WING . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ASSEMBLETHE FUSELAGE . . . . . . . . . . . . . . . . . . . . . .9
Install the Main Landing Gear . . . . . . . . . . . . . . . . . . .9
Install the Stabs & Elevators . . . . . . . . . . . . . . . . . . . .9
Install the Rudder. . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Install the Rudder Servos. . . . . . . . . . . . . . . . . . . . . .12
Complete the Rudder Control Installation . . . . . . . . .15
Install the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Install the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLTHE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . .18
Pitts Style Muffler Installation. . . . . . . . . . . . . . . . . . .19
Canister Muffler Installation . . . . . . . . . . . . . . . . . . . .19
Tuned Pipe Installation. . . . . . . . . . . . . . . . . . . . . . . . 21
MOUNTTHE COWLING AND DUMMY ENGINE . . . . . . 21
INSTALLTHE MAIN &TAILWHEELS . . . . . . . . . . . . . .23
COMPLETETHE RADIO INSTALLATION . . . . . . . . . . .24
INSTALLTHE CANOPY, PILOT
AND INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . .25
APPLYTHE DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .26
GETTHE MODEL READYTO FLY . . . . . . . . . . . . . . . . . 27
Check the Control Directions . . . . . . . . . . . . . . . . . . . 27
Set the Control Throws. . . . . . . . . . . . . . . . . . . . . . . . 27
Proper Pushrod Hookup . . . . . . . . . . . . . . . . . . . . . . 27
Balance the Model (C.G.). . . . . . . . . . . . . . . . . . . . . .28
Balance the Model Laterally. . . . . . . . . . . . . . . . . . . .29
PREFLIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Identify Your Model. . . . . . . . . . . . . . . . . . . . . . . . . . .29
Charge the Batteries . . . . . . . . . . . . . . . . . . . . . . . . .29
Balance Propellers. . . . . . . . . . . . . . . . . . . . . . . . . . .29
Ground Check and Range Check . . . . . . . . . . . . . . .29
ENGINE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . .29
AMA SAFETY CODE EXCERPTS . . . . . . . . . . . . . . . . .30
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Radio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
FLYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel Mixture Adjustments . . . . . . . . . . . . . . . . . . . . . 31
Takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
TABLE OF CONTENTS
INTRODUCTION
For the latest technical updates or manual corrections to the
Yak-55M visit the Great Planes web site at www.greatplanes.
com. Open the “Airplanes” link, then select the Yak-55M ARF.
If there is new technical information or changes to this model a
“tech notice” box will appear in the upper left corner of the page.
Academy of Model Aeronautics
If you are not already a member of the AMA, please join! The
AMA is the governing body of model aviation and membership
provides liability insurance coverage, protects modelers’ rights
and interests and is required to fly at most R/C sites.
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302-9252
Ph. [phone]
Fax [phone]
Or via the Internet at: http://www.modelaircraft.org
IMPORTANT!!! Two of the most important things you can
do to preserve the radio controlled aircraft hobby are to avoid
flying near full-scale aircraft and avoid flying near or over
groups of people.
International Miniature Aircraft Assoc.
The Great Planes Yak-55M is an excellent sport-scale model
and is eligible to fly in IMAA events. The IMAA (International
Miniature Aircraft Association) is an organization that promotes
non-competitive flying of giant-scale models. If you plan to
attend an IMAA event, obtain a copy of the IMAA Safety Code
by contacting the IMAA at the address or telephone number
below, or by logging on to their web site at:
www.fly-imaa.org/imaa/sanction.html.
IMAA
205 S. Hilldale Road
Salina, KS 67401
[phone]

3
SAFETY PRECAUTIONS
ProtectYour Model,Yourself & Others …
FollowThese Important Safety Precautions
1. Your Yak-55M should not be considered a toy, but rather a
sophisticated, working model that functions very much like
a full-size airplane. Because of its performance capabilities,
the Yak-55M, if not assembled and operated correctly, could
possibly cause injury to yourself or spectators and damage
to property.
2. You must assemble the model accordingtothe instructions.
Do not alter or modify the model, as doing so may result in
an unsafe or unflyable model. In a few cases the instructions
may differ slightly from the photos. In those instances the
written instructions should be considered as correct.
3. You must take time to build straight, true and strong.
4. You must use an R/C radio system that is in good condition,
a correctly sized engine, and other components as specified
in this instruction manual. All components must be correctly
installed so that the model operates correctly on the ground
and in the air. You must check the operation of the model
and all components before every flight.
5. If you are not an experienced pilot or have not flown this type
of model before, we recommend that you get the assistance
of an experienced pilot in your R/C club for your first flights.
If you’re not a member of a club, your local hobby shop has
information about clubs in your area whose membership
includes experienced pilots.
6. While this kit has been flight tested to exceed normal use,
if the plane will be used for extremely high stress flying,
such as racing, or if an engine larger than one in the
recommended range is used, the modeler is responsible
for taking steps to reinforce the high stress points and/or
substituting hardware more suitable for the increased stress.
7. WARNING: The cowl and wheel pants included in this kit
are made of fiberglass, the fibers of which may cause eye,
skin and respiratory tract irritation. Never blow into a part
(wheel pant, cowl) to remove fiberglass dust, as the dust
will blow back into your eyes. Always wear safety goggles,
a particle mask and rubber gloves when grinding, drilling
and sanding fiberglass parts. Vacuum the parts and the
work area thoroughly after working with fiberglass parts.
We, as the kit manufacturer, provide you with a top quality,
thoroughly tested kit and instructions, but ultimately the
quality and flyability of your finished model depends on how
you build it; therefore, we cannot in any way guarantee the
performance of your completed model, and no representations
are expressed or implied as to the performance or safety of
your completed model.
Remember:Take your time and follow the instructions to
end up with a well-built model that is straight and true.
DECISIONS YOU MUST MAKE
This is a partial list of items required to finish the Yak-55M that
may require planning or decision making before starting to
build. Order numbers are provided in parentheses.
Radio Equipment
A five-channel radio is the minimum requirement to fly the Yak-
55M. However, it is recommended that you use a computer
radio with more than five channels. We would recommend at
least a seven channel radio with mixing capabilities and inputs
to put all of the servos on their own channel instead of using
“Y” connectors. When choosing servos be sure to use high
quality servos with torque ratings that are equal or greater
than those listed here.The Yak has very large control surfaces
that will strain inexpensive or lower than recommended torque
rated servos.
Radio Recommendations
❍Futaba®7C (FUTJ67**)
❍Futaba 10C (FUTJ9150)
❍Futaba 10CAG (FUTK9255)
Servo Recommendations
❍Ailerons – Minimum rating of 150 oz-in. Two required.
Futaba 9155 (FUTM0215)
❍Elevator – Minimum rating of 150 oz-in. Two required.
Futaba 9155 (FUTM0215)
❍Rudder – Minimum rating of 250 oz-in. One required.
Futaba 9156 (FUTM0216)
(The rudder can also be controlled with two servos
ganged together. Each servo should have at least a
125 oz-in or greater rating if you choose the tandem
servo method.)
❍Throttle and choke – Any precision servo of at least 30
oz-in is acceptable. Futaba 9001 (FUTM0075)
Battery Recommendations
❍Receiver battery with a minimum capacity of 4.8V and
3000 mAh HCAM6355)
❍Ignition battery with a minimum capacity of 1000 mAh
Engine Recommendations
The recommended engine size range for the Yak-55M is a 50
to 55 cc two-stroke gasoline engine.The DLE™55 (DLEG0055)
is a perfect choice for this airplane. This engine provided
enough power to hover and pull straight out from the hover
when coupled with an APC 22x10 propeller (APCQ2201).

4
Muffler Recommendations
This airplane has been designed to accommodate a wide
variety of muffler configurations. The stock muffler and Pitts
style mufflers will require cutting some of the cowl to provide
clearance. We have also provided a tunnel that can be used
with either a canister or tuned pipe. We flew our test model
with the canister. This provided very good power and quiet
flights. The choice is yours. The following are some of the
available mufflers that will work with the Yak-55M:
❍Bison Inverted Wrap Around Pitts Muffler (BISG1052)
❍KS Canister Model 86 with KS Flexible header
❍KS Tuned Pipe Model 1060 with KS Flexible header
ADDITIONAL ITEMS REQUIRED
Required Hardware & Accessories
This is the list of hardware and accessories required to finish
the Yak-55M. Order numbers are provided in parentheses.
❍1/2 oz. [15g] Thin Pro™CA (GPMR6001)
❍1 oz. [30g] Medium Pro CA+ (GPMR6008)
❍1/2 oz. [15g] Thick Pro CA- (GPMR6013)
❍Pro 30-minute epoxy (GPMR6047)
❍Pro 6-minute epoxy (GPMR6045)
❍Super RC Z 56 glue (JOZR5007)
❍Drill bits: 1/16" [1.6mm], 3/32" [2.4mm], 1/8" [3.2mm],
3/16" [4.8mm], 13/64" [5.2mm
❍#1 Hobby knife (HCAR0105)
❍#11 blades (5-pack, HCAR0211)
❍Masking tape (TOPR8018)
❍Microballoons (TOPR1090)
❍Threadlocker thread locking cement (GPMR6060)
❍Denatured alcohol (for epoxy clean up)
❍R/C foam rubber (1/4" [6mm] - HCAQ1000, or 1/2"
[13mm] - HCAQ1050
❍3’ [900mm] gasoline fuel tubing (GPMQ4135)
❍6" [150mm] servo extension (HCAM2701 for Futaba)
❍Four - 12" [300mm] servo extension (HCAM2711
for Futaba)
❍Two - 36" [914mm] servo extension (HCAM2726
for Futaba)
❍Two - 1-1/2" [38mm] heavy duty servo arm
(FUTM2118)
❍Two - 1" [25mm] heavy duty servo arm (FUTM2120)
❍Two - Heavy duty switch harness (FUTM4385)
❍Dubro®Fuel Line Barb (DUB0670)
❍Ernst Futaba charge jack (ERNM3001)
Optional Supplies & Tools
Here is a list of optional tools mentioned in the manual that
will help you build the Yak-55M.
❍21st Century®sealing iron (COVR2700)
❍21st Century iron cover (COVR2702)
❍2 oz. [57g] spray CA activator (GPMR6035)
❍Epoxy brushes (6, GPMR8060)
❍Mixing sticks (50, GPMR8055)
❍Mixing cups (GPMR8056)
❍Hobbico®Duster™can of compressed air (HCAR5500)
❍Rotary tool such as Dremel®
❍AccuThrow™Deflection Gauge (GPMR2405)
IMPORTANT BUILDING NOTES
●There are three types of screws used in this kit:
Sheet Metal Screws are designated by a number and a
length. For example #6 ×3/4" [19mm].
This is a number six screw that is
3/4" [19mm] long.
Machine Screws are designated by a number, threads
per inch, and a length. For example
4-40 ×3/4" [19mm].
This is a number four screw that
is 3/4" [19mm] long with forty
threads per inch.
Socket Head Cap Screws (SHCS) are designated by
a number, threads per inch, and a length. For example
4-40 × 3/4" [19mm].
This is a 4-40 SHCS that is 3/4"
[19mm] long with forty threads
per inch
●When you see the term test fitin the instructions, it means
that you should first position the part on the assembly
without using any glue, then slightly modify or custom fit
the part as necessary for the best fit.
●Whenever the term glue is written you should rely upon
your experience to decide what type of glue to use. When
a specific type of adhesive works best for that step, the
instructions will make a recommendation.
●Whenever just epoxy is specified you may use either
30-minute (or 45-minute) epoxy or 6-minute epoxy. When
30-minute epoxy is specified it is highly recommended that
you use only 30-minute (or 45-minute) epoxy, because you
will need the working time and/or the additional strength.
●Photos and sketches are placed before the step they refer
to. Frequently you can study photos in following steps to
get another view of the same parts.

5
●The Yak-55M is factory-covered with Top Flite®MonoKote®
film. Should repairs ever be required, MonoKote can be
patched with additional MonoKote purchased separately.
MonoKote is packaged in six-foot rolls, but some hobby
shops also sell it by the foot. If only a small piece of MonoKote
is needed for a minor patch, perhaps a fellow modeler
would give you some. MonoKote is applied with a model
airplane covering iron, but in an emergency a regular iron
could be used. A roll of MonoKote includes full instructions
for application. Following are the colors used on this model
and order numbers for six foot rolls.
True Red (TOPQ0227) Black (TOPQ0208)
Jet White (TOPQ0204) Metallic Platinum (TOPQ0408)
KIT INSPECTION
Before starting to build, take an inventory of this kit to make
sure it is complete, and inspect the parts to make sure they
are of acceptable quality. If any parts are missing or are not
of acceptable quality, or if you need assistance with assembly,
contact Product Support.When reporting defective or missing
parts, use the part names exactly as they are written in the
Kit Contents list.
Great Planes Product Support
3002 N Apollo Drive, Suite 1 Ph: [phone], ext. 5
Champaign, IL 61822 Fax: [phone]
E-mail: airsuppor[email protected]
KIT CONTENTS
1. Fuselage
2. Cowl
3. Canopy
4. Stabilizers with Elevators
5. Tail Wheel Assembly
6. Rudder
7. Stabilizer Tubes
8. Fuel Tank
9. Wheel Spats
10. Wheels
11. Landing Gear
12. Dummy Engine
13. Right Wing
14. Left Wing
15. Wing Tube
1
6
2
4
9
10
11
12
13 14
15
8
7
3
5

6
ORDERING REPLACEMENT PARTS
Replacement parts for the Great Planes Yak-55M ARF are
available using the order numbers in the Replacement Parts
List that follows.The fastest, most economical service can be
provided by your hobby dealer or mail-order company.
To locate a hobby dealer, visit the Great Planes web site at
www.greatplanes.com. Select “Where to Buy” in the menu
across the top of the page and follow the instructions provided
to locate a U.S., Canadian or International dealer.
Parts may also be ordered directly from Hobby Services by
calling [phone], or via facsimile at [phone], but
full retail prices and shipping and handling charges will apply.
Illinois and Nevada residents will also be charged sales tax. If
ordering via fax, include a Visa®or MasterCard®number and
expiration date for payment.
Mail parts orders Hobby Services
and payments 3002 N Apollo Drive, Suite 1
by personal check to: Champaign IL 61822
Be certain to specify the order number exactly as listed in the
Replacement Parts List. Payment by credit card or personal
check only; no C.O.D.
If additional assistance is required for any reason contact
Product Support
by e-mail at productsuppor[email protected]
or by telephone at [phone]
Order No. Description
REPLACEMENT PARTS LIST
GPMA4050 Fuselage
GPMA4051 Wing
GPMA4052 Horizontal Stabilizers
GPMA4053 Rudder
GPMA4054 Cowl
GPMA4055 Landing Gear
GPMA4056 Gear Spats
GPMA4057 Canopy
GPMA4058 Canopy Hatch
GPMA4059 Tail Wheel Assembly
GPMA4060 Decals
GPMA4061 Wing Joiner Tube
PREPARATIONS
❏1. If you have not done so already, remove the major
parts of the kit from the box and inspect for damage. If any
parts are damaged or missing, contact Product Support at
the address or telephone number listed in the “Kit Inspection”
section on page 5.
❏2. Use a covering iron with a covering sock on high heat
to tighten the covering if necessary. Do this for all of the
components of the model. Apply pressure over sheeted areas
to thoroughly bond the covering to the wood.
ASSEMBLE THE WING
Note:Throughout this instruction manual you will be instructed
to use screws to secure different parts.In all cases, whenever
a screw is threaded into wood sheeting or wood blocks, we
recommend that you install the screw and then removeit.Apply
a drop of thin CA glue into the hole to harden the threads.After
the glue has hardened, re-install the screw. Following this
step will insure that you have a solid thread for your screws.
Whenever a screw is threaded into a blind nut or a nut is
installed onto a screw, it is recommended that you always
apply a drop of thread locker to them.
Begin with your right wing panel first so your assembly
matches the photos in the manual.
❏❏1. Install a 12" [305mm] servo extension to your aileron
servo. Secure it with heat shrink tubing, tape or other method
for securing them together.

7
❏❏2. Inside the aileron servo compartment you will find a
string. Tie the string to the servo lead. The other end of the
string is taped to the root wing of the rib. Pull the leads through
the wing and then tape the servo lead to the wing to prevent
it from falling back into the wing.
❏❏3. Place your servo onto the mounting blocks. Drill a
1/16" [1.6mm] hole through the servo mounting tabs into the
mounting blocks. Secure the servos to the mounting blocks
with the screws that came with your servos. Note: When
installing the servo into the wing, the end of the servo with the
spline should be located towards the trailing edge of the wing.
❏❏4.The aileron servo
will require a 1" [25mm]
servo arm to get the
required aileron throw.
We recommend that a
high strength metal
servo arm be used. For
our model we used the aluminum Futaba arm (FUTM2120).
Open up the outermost hole in the servo arm by drilling a 1/8"
[3.2mm] hole through it.
❏❏5. Install the servo
arm to the servo as
shown. Be sure to apply
thread locker to the
spline screw.
Hinge Line Hinge Line
CORRECT INCORRECT
Hi
❏❏6. Located in the aileron is a plywood mounting plate.
If you look at the control surface at a slight angle you will be
able to see the plate through the covering. Draw a line from
the outer hole of the servo horn perpendicular to the hinge
line with a felt tip marker. Place a large nylon black control
horn on the plate, in line with the line you have drawn. Position
the control horn on the hinge line as shown in the illustration.
Drill a 3/32" [2.4mm] hole through each of the holes in the
control horn. Drill only through the plywood plate. Do not drill
through the top of the control surface. Mount the horn with
four #4 x 1/2" [13mm] screws.

8
4-40 Bolt
Ball Swivel
4-40 Nut
4-40 Nut Brass Bushing
❏❏7. Locate all of the components shown in the picture, a
4-40 x 5 3/4" [146mm] pushrod wire and an additional 4-40 nut.
Examine the diagram that shows the proper way to assemble
the swivel ball link. Mount the swivel ball link into the hole you
drilled in the servo arm.
❏❏8.The photo shows how your pushrod assembly should
look. Center the aileron and the aileron servo. Install the servo
arm onto the servo and the solder clevis into the second most
outer hole of the control horn. Mark where to cut the pushrod
wire. Cut the wire on the mark you made. Remove all of the
components of the pushrod wire from the clevises and the
control horn. Solder the pushrod wire to the solder clevis using
the soldering “Hot Tip” that follows.
How to Solder
1. Use denatured alcohol or other solvent to thoroughly
clean the pushrod. Roughen the end of the pushrod with
coarse sandpaper where it is to be soldered.
2. Apply a few drops of soldering flux to the end of the
pushrod, then use a soldering iron or a torch to heat it.
“Tin” the heated area with silver solder by applying the
solder to the end. The heat of the pushrod should melt the
solder – not the flame of the torch or soldering iron – thus
allowing the solder to flow. The end of the wire should be
coated with solder all the way around.
3. Place the clevis on the end of the pushrod. Add another
drop of flux, then heat and add solder. The same as
before, the heat of the parts being soldered should melt
the solder, thus allowing it to flow. Allow the joint to cool
naturally without disturbing. Avoid excess blobs, but make
certain the joint is thoroughly soldered. The solder should
be shiny, not rough. If necessary, reheat the joint and allow
to cool.
4. Immediately after the solder has solidified, but while it
is still hot, use a cloth to quickly wipe off the flux before
it hardens. Important: After the joint cools, coat the joint
with oil to prevent rust. Note: Do not use the acid flux that
comes with silver solder for electrical soldering.
This is what a properly soldered clevis looks like –
shiny solder with good flow, no blobs and flux removed.
❏❏9. After the solder cools, install the pushrod assembly
to the aileron servo and the aileron. Be sure to use thread
locker on the nuts and a silicone clevis keeper on the clevis.

9
❏❏10. Glue a 5/16" x 1" [7.9mm x 25mm] wood dowel into
the two outermost holes in the wing root. The dowel should
extend out of the wing 1/2" [13mm].
❏11. Repeat steps 1- 10 for the left wing panel.
ASSEMBLE THE FUSELAGE
Install the Main Landing Gear
The following steps explain mounting the main landing gear.
We will finish the tail wheel gear and installation of the wheels
later in the manual.You will find the fuselage much easier to
work with when the landing gear is installed.
❏1. Slide the landing gear into the fuselage on both the left
and right side of the fuselage.The straight side of the landing
gear should be towards the front of the fuselage.
❏2. Secure the landing gear with 8-32 x 3/4" SHCS, #8 lock
washers and #8 flat washers. Be sure to apply thread locker
to the screw threads.
Install the Stabs & Elevators
❏1. Including the servo lead from the servo, you will need
58" [1475mm] of wire to reach from the elevator to the radio
compartment in the airplane. For a Futaba servo this means
you will need some combination of servo leads to equal 45"
[1145mm] or more.We used a 12" [305mm] and 36" [914mm]
lead plugged together. Be sure to secure all of the connections
with heat shrink tubing, tape or some other method to secure
all of the connections. If you have the ability make your own
leads you may choose to do this and eliminate one of the
connections. Make two of these extensions. Install the rubber
servo pads and metal grommets on the servos.

10
❏ ❏
2. To achieve proper elevator control
you will need to use a 1-1/2" heavy duty servo
arm. We used the Futaba aluminum arm
(FUTM2118). Enlarge the hole that is 1-1/4"
[32mm] from the center of the servo spline
with a 1/8" [3.2mm] drill. (The 1-1/4" [32mm]
dimension is approximate.You may find that
for your brand of servo, the holes might be
spaced slightly different than the Futaba.
Open up the hole closest to this dimension.)
❏❏3. Center your servo and then install the arm to the servo.
Remove the servo tray cover from the left stab. Place the
servo on the tray with the servo arm centered in the slot. Glue
a 5/16" x 9/16" x 13/16" [8mm x 14mm x 21mm] wood servo
block on each side of the servo.
❏❏4. Drill a 1/16" [1.6mm]
hole through each of the
mounting tabs of your servo.
Mount the servo with the
hardware that came with
your servos.
❏❏5. Drill a 1/16" [1.6mm] hole through the servo cover
into the hardwood blocks you glued in place. Install a #2 x 3/8"
[9.5mm] wood screw into each block to secure them.
❏❏6. Guide the servo lead through the stab exiting through
the root rib. Secure the servo cover in place with four #2 x 3/8"
[9.5mm] screws and #2 flat washers.
❏❏7. Cut one of the 4-40 x 5-3/4" [146mm] pushrod wires
to a length of 2-3/4" [70mm]. Using the solder technique used
on the ailerons, solder the unthreaded end of the wire to the
4-40 threaded solder connector.
❏❏8. Assemble the pushrod as shown in the photo. Be sure
to use thread locker on the nuts when doing the final assembly.
Install the nylon swivel ball link to the servo arm with a 4-40
x 1/2" [13mm] screw and 4-40 nut.

11
Hinge Line Hinge Line
CORRECT INCORRECT
Hi
❏❏
9. Using the pushrod wire as a guide, locate the plywood
plate in the elevator servo. Position the large nylon black control
horn on the plate, in line with the pushrod wire. Position the
control horn on the hinge line the same way you did for the
ailerons. Drill a 3/32" [2.4mm] hole through each of the holes
in the control horn. Drill only through the plywood plate. Do
not drill through the top of the control surface. Mount the
horn with four #4 x 1/2" [13mm] screws.
❏❏10. Install the servo pushrod as shown. Make any
adjustments required to the arm to get the proper length for
the pushrod so when the servo is centered, the elevator is
aligned with the stabilizer.
❏11. Repeat steps 2-10 for the right side stabilizer / elevator.
❏12. Locate the two carbon fiber stab tubes. Slide the shorter
length tube into the forward most hole in the rear of the fuselage
and the longest tube in the rear hole in the fuse. Through the
opening in the back of the fuselage, install the servo leads
into the fuselage up to the radio compartment and then test
fit the stabs to the fuselage.
❏13. When you are satisfied with the fit, glue the stabs
one side at a time to the fuselage with 30-minute epoxy.
Apply the glue to the tubes, the root rib of the stab and the
fuselage side. Clean any excess epoxy with a paper towel
and rubbing alcohol. Use masking tape to hold the stabs
tight to the fuselage while the glue is curing.

12
Install the Rudder
❏
1. Without using any
glue, install four hinges
into the holes in the
trailing edge of the rudder.
Note that the pivot point
of each hinge must align
with the center of the
trailing edge. To achieve
this alignment, the hinges
will be fairly deep in the fin.
Also note that the hinges
must be perpendicular to
the leading edge.
❏2. Again without glue,
test fit the rudder to the fin. Remove the rudder and all the
hinges. Add a small drop of oil to the pivot point on the hinges.
This will prevent the epoxy from adhering to the pivot point.
Make sure oil does not get on the gluing surface of the hinge.
If it does, clean the oil off with a paper towel square dampened
with denatured alcohol.
❏3. Mix up approximately 1/4 oz. [7.4cc] of 30-minute epoxy.
Use a toothpick to thoroughly apply the epoxy in the holes in
the fin and rudder. Use the toothpick to get the epoxy out of
the opening of the holes in the rudder and fin so it doesn’t get
into the hinge pin. Wipe away any excess epoxy around the
outside of the holes with a couple of the small paper towel
squares dampened with denatured alcohol.
❏
4. Use the toothpick to apply epoxy to the ends of the rudder
hinges that go into the fin. Insert each hinge into the fin and
wipe away any excess epoxy that squeezes out of the hole.
❏5. Apply epoxy to the other end of the hinges. Join the
rudder to the fin, pushing the hinges only about 3/4 of the
way into the rudder. Use a toothpick to wipe away any epoxy
that squeezes out. Then fit the rudder the rest of the way in.
❏6. Move the rudder left and right to align the hinges. If
needed, use a length of masking tape to hold the rudder to
the fin. Allow the glue to fully cure.
Install the Rudder Servos
We have designed this airplane with the option to use one servo
with 250 oz-in. of torque or to use two, lower strength servos
in tandem. If you are more of a sport flyer and not an aspiring
3-D pilot, you can use a single servo with approximately 125
oz-in. You will need to make a decision on the number of
servos you will be using. Should you decide to use a single
servo and later decide you would like to use two servos you
can add the second servo later.
❏1. Modify two large black nylon control horns as shown.
This is easily completed with a high speed motor tool, small
belt sander or a sanding block with coarse sandpaper. As
you did with the ailerons horns, locate the plywood plate on
each side of the rudder. Position the horns over the plates.
Drill a 3/32" [2.4mm] hole through each of the holes in the
control horn. Drill only through the plywood plate. Do not
drill through the control surface. Mount the horn with four
#4 x 1/2" [13mm] screws. Do this on both sides of the rudder.
SINGLE SERVO INSTALLATION
If you will be installing two servos, skip ahead to, “Two
Servo Installation”.
❏❏2. For the rudder
servo arm installation
you will need one of
the aluminum servo
arms included in the kit
and one of the round
servo disks included
with your radio system.
The round servo disk
needs to be at least 1"
[25mm] in diameter.

13
❏❏3. Position the aluminum servo arm on top of the disk.
Drill a 3/32" [2.4mm] hole through the aluminum arm and
through the disk. Do this for all four holes. Secure the arm to
the disk with four 2-56 x 1/2" [13mm] machine screws and
2-56 nuts. Be sure to secure the nuts with a drop of thread
locker. After the nuts are secure, cut off the thread from the
bolt that extends above the nut. This can be done with a high
speed motor tool or a good side cutter.
❏ ❏
4. Install your servo into the rear rudder servo tray using
the hardware that came with your servo. Center the servo and
then install the servo arm.
❏❏5. Use wire cutters to cut the supplied braided cable into
two equal lengths. Slide a small tube (called a swage) over the
end of one cable. Then, guide the end of the cable through
the threaded brass coupler and the back through the swage.
❏❏6. Wrap the cable back around the swage and back
through the swage.
❏❏7. Use pliers to pull the cable from the first loop to reduce
the size of the second loop. Squeeze the swage with pliers
and then cut off the excess wire.
❏8. Repeat steps 2 – 7 for the remaining cable.
❏9 Install a 4-40 thread clevis, 4-40 nut and a silicone clevis
keeper onto the threaded connectors.
❏10. Inside of the fuselage are two white plastic guide tubes.
Slide a wire into each of the tubes until they exit out the
fuselage sides. Connect the clevis to the hole in the aluminum
servo arm. Note: When you connect the clevises to the arm
be sure that the wires cross each other. In other words, the
wire attached to the right side of the servo arm exits the left
side of the fuselage and the left side clevis exits out the right
side of the fuselage.
If you have completed the single servo installation, skip ahead
to, “Complete the Rudder Control Installation”.

14
DOUBLE SERVO INSTALLATION
❏ ❏
1. For the dual rudder
servo arm installations
you will need two of the
aluminum servo arms
included in the kit and two
of the round servo disks
included with your radio
system. The round servo
disk needs to be at least 1"
[25mm] in diameter.
❏❏2. Position the aluminum servo arm on top of the disk.
Drill a 3/32" [2.4mm] hole through the aluminum arm, through
the disk. Do this for all four holes. Secure the arm to the disk
with four 2-56 x 1/2" [13mm] machine screws and 2-56 nuts.
Be sure to secure the nut with a drop of thread locker. After the
nuts are secure, cut off the thread from the bolt that extends
above the nut. This can be done with a high speed motor tool
or a good side cutter. Do this for both servo arms.
❏❏3. Install your servos into the rudder servo tray using
the hardware that came with your servo. Center the servos
and then install the servo arm.
❏❏4. Locate two 4-40 x 5-3/4" [146mm] thread pushrod wires.
Cut off the threaded end of the wire leaving an unthreaded
wire 3-1/2" [89mm] in length.
❏❏5. Locate four heavy duty screw lock connectors, metal
retainer clips and 4-40 x 1/4" [6mm] socket head cap screws.
Install the connector into the outer hole of the servo arms and
secure them with the retainer clips. Center both servos and
then install the two 4-40 wires into the connectors. Secure
the rods with the 4-40 screws. Be sure to apply a couple of
drops of thread locker to each screw.
❏❏6. Use wire cutters to cut the supplied braided cable into
two equal lengths. Slide a small tube (called a swage) over the
end of one cable. Then, guide the end of the cable through
the threaded brass coupler and the back through the swage.
❏❏7. Wrap the cable back around and through the swage.

15
❏❏8. Use pliers to pull the cable from the first loop to reduce
the size of the second loop. Squeeze the swage with pliers
and then cut off the excess wire. Do this for both wires.
❏❏9. Install a 4-40 thread clevis, 4-40 nut and a silicone
clevis keeper onto the threaded connectors.
❏❏10. Inside of the fuselage are two white plastic guide
tubes. Slide a wire into each of the tubes until they exit out the
fuselage sides. Connect the clevis to the hole in the aluminum
servo arm. Note: When you connect the clevises to the arm,
be sure that the wires cross each other. In other words, the
wire attached to the right side of the servo arm exits the left
side of the fuselage and the left side clevis exits out the right
side of the fuselage.
Complete the Rudder Control Installation
❏1. Attach a clevis to the outer hole of the rudder control
horns that you modified. Center the rudder and the rudder
servo. Attach the wire to each of the clevis assemblies and
then secure the wire with the swages using the same technique
used on the connection at the servo.
❏2. Adjust the tension of the wires by turning the clevises in
or out on the connector. Then, lock the nut against the clevis.
Be sure to apply a drop of thread locker to the nut.
Install the Engine
The following instructions cover the installation of the DLE55.
Other engines will require similar installation.You will need to
determine the proper mounting hole positions and location for
the throttle connections for your choice of engine.
MOUNTTHE ENGINE AND INSTALLTHETHROTTLE
AND CHOKE SERVOS
The following instructions will show how to install a servo
activated choke. We know some modelers may wish to use
some sort of a manual linkage. It is recommended that you
read the installation instructions and then decide which method
you prefer. We will not be showing installation of a manual
linkage. Most modelers will find that this is easy to do and
requires little explanation.
❏1. Locate the paper mounting pattern on page 32 of this
manual.Tape the pattern to the firewall, aligning the reference
lines on the paper pattern with the reference lines on the
firewall. When positioning it, the bolt hole pattern should be
aligned as shown.
❏2. Drill a 1/8" [3.2mm] pilot hole through the center of each
mounting hole. Remove the paper pattern and drill a 13/64"
[5.2mm] hole through the firewall on each of the pilot holes

16
you drilled. (13/64 [5.2mm] is required as a clearance hole for
a 10-24 bolt. If you are mounting a different engine, be sure to
check the size of the mounting bolts before drilling the holes).
❏
3. Install the fiber servo arm to the carburetor of the engine.
Install a 2-56 ball link and secure it with a 2-56 nut on the
throttle. If you will be using our choke method, then install a
ball and nut to the choke as well.
❏4. Using the hardware with the engine, mount the engine
to the firewall.
❏5. Cut one half off of one of the two nylon ball links included
in the kit. Snap the nylon link that you cut onto the choke
and the remaining nylon link onto the throttle. Use the links
as reference and mark the firewall where the pushrods will
pass through. Drill a 3/16" [4.8mm] hole through each of the
marks. If you have an extended drill bit you can do this without
removing the engine. If not you will need to remove and then
reinstall the engine.
❏6. Locate two 1/4" x 3/8" x 3/4" [6mm x 10mm x 19mm]
hardwood blocks. Glue them in place over the choke servo
opening as shown.
❏7. Mount the throttle and choke servos as shown here. If
you are not using a choke servo you can mount the throttle
servo in either of the two openings.
❏8. Locate the plywood guide tube support and two 12"
[305mm] gray plastic pushrod tubes. Roughen approximately

17
1" [25mm] on one end of each of the tubes with 200 grit
sandpaper. Insert the tubes into the hole you drilled in the
firewall. Be sure to insert the smooth end of the tube first so
that the roughened end contacts the firewall. Apply glue to
the roughened end of the tubes and then make the end of
the tube flush with the firewall.
❏9. Slide the plywood guide tube support over both tubes.
(If you are not installing the choke servo then just slide the
tube over the single pushrod tube.) Slide it forward until it is
at the former as shown. Do not glue the support in place!
Cut the tubes so that they end approximatey 2" [51mm] before
the servo arms.
❏10. Thread a 2-56 x 1" [25mm] threaded rod into the end
of two white nylon inner pushrod tubes (You only need to do
one tube if you are not using the servo activated choke) and
then screw the nylon ball link connectors to the wires. Slide
the pushrods into the plastic tubes you glued to the firewall.
Snap the ball links onto the balls. Be sure that you use the
pushrod with the shortened ball link for the choke.
❏
11. Cut the inner white nylon pushrod to the proper length for
the position of the servos. Install a 2-56 x 1" [25mm] threaded
rod into the end of the pushrod tube followed by a 2-56 nut
and a 2-56 metal clevis and silicone clevis keeper. When you
are satisfied with the installation, glue the plywood guide tube
to the bulkhead. Position it so that the tubes make as straight
an exit through the firewall as possible.
Install the Fuel Tank
❏1. Assemble the fuel tank stopper assembly with the fuel
tubes as shown. The easiest way is to first solder a fuel line
barb (not included, Dubro Fuel Line Barb DUB0670) at the

18
end of all three tubes. Insert the tubes into the stopper with the
metal plates, and then solder a barb onto the other end of the
two short tubes. Bend the vent tube and connect the pickup
and gas compatible fueling/defueling lines (not included) to
the short tubes. Connect the clunks to the Tygon Fuel lines
(not included) and secure the lines to the clunk and brass
tubing with the included small tie straps.
❏2. Install the fuel tank stopper assembly in the fuel tank.
Check that the clunks move around freely in the fuel tank.
Tighten the fuel tank stopper screw.
❏3. Install fuel lines onto the brass tubes from the fuel tank.
To route the fuel lines where shown, you will need to use a
12" [305mm] length of tubing on the fill and vent line and a 6"
[152mm] length on the carburetor line.
❏4. Drill a 1/4" [25mm] hole through the firewall in line with
the carburetor inlet.
❏5. Install the fuel tank onto the tray in the fuselage. Secure
the tank with two large plastic tie wraps. Feed the lines through
the firewall. Make sure when you insert the tank that the vent
line is at the top of the tank.
❏6. Route the carburetor line through the firewall, trim it as
needed and attach it to the carburetor. Drill two 1/4" [25mm]
holes through the bottom of the firewall box as shown. Pass
the vent and fill lines through the holes. To secure the fill and
vent line we drilled additional holes in the fuselage.You may
wish to do this or secure the lines with a method of your choice.
Plug the fill line with the aluminum fuel plug.
❏
7. Install the ignition battery and module following the
instructions with the engine. We have provided four hooks for
securing the module and battery. Be sure to secure all of the
electrical connections between the ignition module, battery
and switch harness. Mount the ignition switch and charge jack
to the fuselage side. We used an Ernst Futaba charge jack
(ERNM3001) for our installation.
INSTALL THE MUFFLER
This airplane is designed to allow you the flexibility of installing
your choice of a Pitts style muffler, canister or a tuned pipe.
For purposes of this manual we will show the full installation
of the canister muffler system and give an overview of the
requirements to install the tuned pipe and Pitts muffler. You
need to decide which system you will use. You might wish to
review the installation instructions before determining which
option is best for you.

19
Pitts Style Muffler Installation
❏1. Remove the two covers from the bottom of the fuselage.
If you will be using the muffler that came with your engine
or using a Pitts style muffler, permanently glue the covers
to the fuselage. If you have thoughts of changing between a
Pitts style muffler and a canister, you might choose to glue
the covers in place with silicone. This would allow the covers
to be cut loose at a later time.
❏2. Mount the muffler to the engine. Be sure the spark plug
lead from the ignition module is not contacting the muffler.
Canister Muffler Installation
❏1. Remove the two covers from the bottom of the fuselage.
These two covers allow you to customize the fuselage for your
choice of muffler, canister or tuned pipe. For a canister, glue
the rear cover in place to the fuselage.
❏2.The kit includes 4 plywood canister/pipe holder and one
24" [610mm] piece of silicone tubing. For the canister you will
be using two of the holders. From the 24" [610mm] silicone
tube, cut eight 1/2" [13mm] length tubes. (The remaining
holders and silicone tubing are for use with the installation of
a tuned pipe).When choosing the plywood holders, notice that
one is slightly taller than the other.You will need one of each.
❏3. Insert eight silicone tubes onto the tabs in the two plywood
holders as shown.

20
❏4. Gather all of the canister components together. Test fit
the canister to the holders. The taller of the plywood holders
should be at the front of the canister and the shorter holder
towards the rear.The canister should fit slightly loose between
the silicone holders.
❏5. Temporarily mount the exhaust header to the engine.
❏6. Test fit the canister and holders into the opening in the
fuselage. When you are satisfied everything fits well, remove
the canister and remove the holders from the canister.
❏7. Insert the taller of the two holders into the fuselage. Glue
it on the seam where the plywood meets balsa wood. Glue
the shorter holder in place 7" [187mm] back from the forward
holder. Make supports for the holders from the 1/4 x 1/4 x 24"
[6mm x 6mm x 610mm] balsa stick included in the kit. Cut
the sticks to length to fit the holders. Glue the sticks to the
holders and the tunnel wall.The canister holders are already
fuel proofed but you should take a few minutes to fuel proof
the sticks. This can be done by brushing a small amount of
epoxy over the bare wood.
❏8. Slide the canister into the holders. Slide the coupling
and the clamps onto the exhaust header and the secure the
header to the engine. Slide the coupler in place so that there
is approximately 1/4" [6mm] between the end of the canister
and the exhaust header. Be sure that the end of the canister
does not hit the back of the tunnel. You need to leave room
for the canister to expand when it gets hot. Be sure the lead
from the ignition module is not contacting the muffler.