Hangar 9 40-Size Floats User manual

Assembly mAnuAl
40-Size Floats

2
Table of Contents
Instructions for Disposal of WEEE by Users in the European Union. . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ContentsofKit ....................................................................3
RequiredToolsandAdhesives........................................................3
WarrantyPeriod ...................................................................4
LimitedWarranty...................................................................4
DamageLimits....................................................................4
SafetyPrecautions .................................................................4
Questions,Assistance,andRepairs ....................................................5
InspectionorRepairs...............................................................5
WarrantyInspectionandRepairs.......................................................5
Non-WarrantyRepairs...............................................................5
Safety,Precautions,andWarnings.....................................................6
UsingtheManual..................................................................6
BeforeStartingAssembly............................................................6
FuselagePreparation ...............................................................7
FloatInstallation...................................................................9
2007 Official AMA National Model Aircraft Safety Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2007 Official AMA National Model Aircraft Safety Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Instructions for Disposal of WEEE by
Users in the European Union
This product must not be disposed of with other waste. Instead, it is the user’s responsibility to dispose of their waste
equipment by handing it over to a designated collection point for the recycling of waste electrical and electronic
equipment. The separate collection and recycling of your waste equipment at the time of disposal will help to conserve
natural resources and ensure that it is recycled in a manner that protects human health and the environment. For more
information about where you can drop off your waste equipment for recycling, please contact your local city office, your
household waste disposal service or where you purchased the product.

3
Contents of Kit
A. HAN4016 Hardware Set
B. HAN4017 Steel Strut Set
C. HAN4018 Pushrod & Tube, Nylon Horn, EZ Connector
D. HAN4019 Float w/o Servo Mount
E. HAN4020 Float w/Servo Mount
Required Tools and Adhesives
Tools
• Drill • Hobby knife
• Covering iron • Sandpaper
• Phillips screwdriver • Drill bit: 5/64-inch (2mm)
• Side cutters • Hex wrench: 1.5mm
• Heat gun • Tie wraps
Adhesives
• 30-minute Epoxy (HAN8002) • Threadlock
• Clear silicone
Radio Equipment
• Standard size servo (JRPS537 or JSP20050) • Y-Harness (JSP98020)
• Charge Receptacle: Futaba (ERN124) • Charge Receptacle: JR (ERN147)
A
B
C
E
D

4
Warranty Period
Exclusive Warranty- Horizon Hobby, Inc., (Horizon) warranties that the Products purchased (the "Product") will be free
from defects in materials and workmanship at the date of purchase by the Purchaser.
Limited Warranty
(a) This warranty is limited to the original Purchaser ("Purchaser") and is not transferable. REPAIR OR REPLACEMENT
AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER. This warranty covers only
those Products purchased from an authorized Horizon dealer. Third party transactions are not covered by this warranty.
Proof of purchase is required for warranty claims. Further, Horizon reserves the right to change or modify this warranty
without notice and disclaims all other warranties, express or implied.
(b) Limitations- HORIZON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NON-
INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCT. THE
PURCHASER ACKNOWLEDGES THAT THEY ALONE HAVE DETERMINED THAT THE PRODUCT WILL SUITABLY MEET
THE REQUIREMENTS OF THE PURCHASER’S INTENDED USE.
(c) Purchaser Remedy- Horizon's sole obligation hereunder shall be that Horizon will, at its option, (i) repair or (ii)
replace, any Product determined by Horizon to be defective. In the event of a defect, these are the Purchaser's exclusive
remedies. Horizon reserves the right to inspect any and all equipment involved in a warranty claim. Repair or replacement
decisions are at the sole discretion of Horizon. This warranty does not cover cosmetic damage or damage due to acts of
God, accident, misuse, abuse, negligence, commercial use, or modification of or to any part of the Product. This warranty
does not cover damage due to improper installation, operation, maintenance, or attempted repair by anyone other than
Horizon. Return of any goods by Purchaser must be approved in writing by Horizon before shipment.
Damage Limits
HORIZON SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR
PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCT, WHETHER SUCH CLAIM
IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. Further, in no event shall the liability of
Horizon exceed the individual price of the Product on which liability is asserted. As Horizon has no control over use,
setup, final assembly, modification or misuse, no liability shall be assumed nor accepted for any resulting damage or
injury. By the act of use, setup or assembly, the user accepts all resulting liability.
If you as the Purchaser or user are not prepared to accept the liability associated with the use of this Product, you are
advised to return this Product immediately in new and unused condition to the place of purchase.
Law: These Terms are governed by Illinois law (without regard to conflict of law principals).
Safety Precautions
This is a sophisticated hobby Product and not a toy. It must be operated with caution and common sense and requires
some basic mechanical ability. Failure to operate this Product in a safe and responsible manner could result in injury
or damage to the Product or other property. This Product is not intended for use by children without direct adult
supervision. The Product manual contains instructions for safety, operation and maintenance. It is essential to read
and follow all the instructions and warnings in the manual, prior to assembly, setup or use, in order to operate correctly
and avoid damage or injury.

5
Questions, Assistance, and Repairs
Your local hobby store and/or place of purchase cannot provide warranty support or repair. Once assembly, setup or
use of the Product has been started, you must contact Horizon directly. This will enable Horizon to better answer your
questions and service you in the event that you may need any assistance. For questions or assistance, please direct your
email to [e-mail], or call 877.504.0233 toll free to speak to a service technician.
Inspection or Repairs
If this Product needs to be inspected or repaired, please call for a Return Merchandise Authorization (RMA). Pack
the Product securely using a shipping carton. Please note that original boxes may be included, but are not designed
to withstand the rigors of shipping without additional protection. Ship via a carrier that provides tracking and insurance
for lost or damaged parcels, as Horizon is not responsible for merchandise until it arrives and is accepted
at our facility. A Service Repair Request is available at www.horizonhobby.com on the “Support” tab. If you do not
have internet access, please include a letter with your complete name, street address, email address and phone number
where you can be reached during business days, your RMA number, a list of the included items, method of payment
for any non-warranty expenses and a brief summary of the problem. Your original sales receipt must also be included
for warranty consideration. Be sure your name, address, and RMA number are clearly written on the outside of the
shipping carton.
Warranty Inspection and Repairs
To receive warranty service, you must include your original sales receipt verifying the proof-of-purchase
date. Provided warranty conditions have been met, your Product will be repaired or replaced free of charge. Repair or
replacement decisions are at the sole discretion of Horizon Hobby.
Non-Warranty Repairs
Should your repair not be covered by warranty the repair will be completed and payment will be
required without notification or estimate of the expense unless the expense exceeds 50% of the retail
purchase cost. By submitting the item for repair you are agreeing to payment of the repair without notification. Repair
estimates are available upon request. You must include this request with your repair. Non-warranty repair estimates will
be billed a minimum of ½ hour of labor. In addition you will be billed for return freight. Please advise us of your preferred
method of payment. Horizon accepts money orders and cashiers checks, as well as Visa, MasterCard, American Express,
and Discover cards. If you choose to pay by credit card, please include your credit card number and expiration date. Any
repair left unpaid or unclaimed after 90 days will be considered abandoned and will be disposed of accordingly. Please
note: non-warranty repair is only available on electronics and model engines.
Electronics and engines requiring inspection or repair should be shipped to the following address:
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
All other Products requiring warranty inspection or repair should be shipped to the following address:
Horizon Product Support
4105 Fieldstone Road
Champaign, Illinois 61822
Please call 877-504-0233 with any questions or concerns regarding this product or warranty.

6
Safety, Precautions, and Warnings
Models are controlled by a radio signal that is subject to interference from many sources outside your control. This
interference can cause momentary loss of control so it is advisable to always keep a safe distance in all directions around
your model, as this margin will help to avoid collisions or injury.
• Always operate your model in an open area away from cars, traffic, or people.
• Avoid operating your model in the street where injury or damage can occur.
• Never operate the model into the street or populated areas for any reason.
• Never operate your model with low transmitter batteries.
• Carefully follow the directions and warnings for this and any optional support equipment (chargers, rechargeable
battery packs, etc.) that you use.
• Keep all chemicals, small parts and anything electrical out of the reach of children.
• Moisture causes damage to electronics. Avoid water exposure to all equipment not specifically designed and protected
for this purpose.
Using the Manual
This manual is divided into sections to help make assembly easier to understand, and to provide breaks between each
major section. In addition, check boxes have been placed next to each step to keep track of each step completed. Steps
with a single box () are performed once, while steps with two boxes () indicate that the step will require
repeating, such as for a right or left wing panel, two servos, etc. Remember to take your time and follow the directions.
Before Starting Assembly
Before beginning the assembly of the 40-size floats, remove each part from its bag for inspection. Closely inspect
the contents for damage. If you find any damaged or missing parts, contact the place of purchase.
If you find any wrinkles in the covering, use a heat gun or sealing iron to remove them. Use caution while working where
the seams overlap to prevent separating the covering.
HAN100 – Heat Gun
HAN150 – Covering Glove
HAN101 – Sealing Iron
HAN141 – Sealing Iron
Sock

7
Required Parts
• Assembled fuselage • Main Strut
• Rear strut support • Gear strap (2)
• Covering
Required Tools and Adhesives
• Drill • Hobby knife
• Covering iron • 30-minute epoxy
• Sandpaper • Phillips screwdriver
• Y-harness • Heat gun
• Drill bit: 5/64-inch (2mm)
• Charge Receptacle: Futaba (ERN124)
• Charge Receptacle: JR (ERN147)
Step 1
Remove the landing gear from your Cub and place it in
a safe place for use later. Use a hobby knife to trim the
covering to allow access inside the fuselage. Only cut
back enough to allow the rear strut support to fit inside
the fuselage.
Note: Use a technique similar to this for most
40-size aircraft when mounting the floats.
Step 2
Test fit the rear strut support inside the fuselage. The
curved plywood will fit tight against the bottom of the
fuselage. Sand the larger block as necessary so the rear
support fits tight in the fuselage.
Step 3
Use 30-minute epoxy to glue the rear strut support in the
fuselage. Allow the epoxy to fully cure before proceeding.
Fuselage Preparation

8
Step 4
Once the epoxy has fully cured, use a covering iron and
the supplied covering to cover over the rear strut support.
Step 5
Attach the main gear to the bottom of the fuselage. Use
the original screws and straps to secure the front of the
strut to the fuselage. The rear will use the original screws,
but you will need to drill four 5/64-inch (2mm) holes to
secure the rear of the strut using the supplied gear straps.
Step 6
Install one end of a Y-harness into the Ernst charge
receptacle. Mount the charge receptacle to the right side of
the fuselage (viewed when sitting in the pilot seat) using
the hardware provided with the receptacle. Connect the Y-
harness to the rudder channel of the receiver and plug the
rudder servo into the remaining lead of the harness.
Fuselage Preparation

9
Required Parts
• Assembled fuselage • Float (right and left)
• Strut mount (4) • Rudder
• Pushrod wire • Clevis
• Steering arm • Servo hatch
• Water rudder mount
• 5/32-inch wheel collar w/setscrew (4)
• 3mm x 8mm machine screw (2)
• 2mm x 10mm sheet metal screw (4)
• 4-40 x 1/2-inch machine screw (20)
• Pushrod connector w/backplate
Required Tools and Adhesives
• Side cutters •Phillips screwdriver
• Hex wrench: 1.5mm • Threadlock
• Servo w/hardware • Clear silicone
• Y-harness
Step 1
Attach the strut mounts to the top of the left and right
floats using four 4-40 x 1/2-inch machine screws for
each strut mount.
Note: Always use threadlock on
metal-to-metal fasteners to prevent
them from vibrating loose.
Step 2
Install the rudder servo into the right float using the
hardware provided with the servo.
Step 3
Attach the water rudder mount to the rear of the right float
using four 4-40 x 1/2-inch machine screws. Slide the
pushrod wire into the pushrod tube threaded end first.
Step 4
Thread a clevis onto the pushrod wire. Use side cutters to
remove any excess arms from the servo horn. Attach the
clevis to the servo arm and secure the arm to the servo.
Float Installation

10
Step 5
Install the pushrod connector to the center hole of the
steering arm using the connector backplate. Make sure the
hole for the screw in the arm is facing toward you and the
connector is installed as shown.
Step 6
Slide the pushrod connector onto the pushrod wire. With
the steering arm in the mount, slide the rudder assembly
up through the mount and through the steering arm.
Step 7
Use the radio to move the rudder servo fully to the right.
With the steering arm almost touching the float, secure the
brass pushrod connector and pushrod wire using a 3mm x
8mm machine screw. Center the servo using the radio and
align the water rudder to the centerline of the float. Secure
the steering arm to the water rudder shaft using a 3mm x
8mm machine screw. Use side cutters to trim the excess
pushrod wire.
Note: Always use threadlock on
metal-to-metal fasteners to prevent
them from vibrating loose.
Step 8
Cut a small notch in the servo hatch to clear the servo
lead. Secure the hatch to the float using four 2mm x
10mm sheet metal screws. Use clear silicone to seal the
opening where the servo lead exits the float.
Float Installation

11
Step 9
Attach the floats to the strut using four 5/32-inch wheel
collars and a 1.5mm hex wrench.
Note: Always use threadlock on
metal-to-metal fasteners to prevent
them from vibrating loose.
Step 10
Plug the servo lead into the Ernst charge jack on the side
of the fuselage. Use tie wraps to secure the servo lead to
the strut.
Step 11
Now that your floats have been installed, you MUST verify
that the Center of Gravity of your model is still correct.
Use the Center of Gravity provided in the manual included
with your particular aircraft.
Important: If installing on a model other
than the Hangar 9 J-3 Cub, the floats
should be installed such that the step
in the float is located 1/2-inch (13mm)
or less behind the CG of the model.
Float Installation

12
Float Flying
Flying from floats can be great fun. There are a few things
to remember when you hit the lake. First, make sure you
pick a location where you can take off and land parallel to
the shore line with no obstructions. You will want to make
sure you are taking off and landing into the wind.
Verify your water rudder is down and the engine is
running. Set the plane into the water and begin to taxi out.
It is common to hold full up elevator (back stick) during
all taxi maneuvers. This helps to eliminate prop splash
and keeps the water rudder deep in the water for improved
steering. You may want to use a high rate for your rudder
during this operation as well. You will switch to a low rate
rudder for takeoff.
Taxi slowly to get the hang of the rudder. Once you have
lined up for takeoff, set your rudder dual rate to low. The
water rudder becomes very effective during takeoff. Apply
full up elevator and apply throttle slowly at first. As the
plane picks up speed, you will notice it coming up on
step. At this time, you can relax the elevator input and fly
off the water the same way you take off from hard ground.
Once in the air, you will find the plane to behave slightly
different than before. The added weight below the model
acts similar to a pendulum effect in flight. It will slightly
effect the aerobatic performance as well. You will notice a
higher power setting from normal due to the added drag
and weight of the floats.
Landing on water is very similar to landing on hard
ground. Set up like you normally would and turn onto
final approach. Maintain power during the approach,
as a plane with floats tends to land slightly faster than
when equipped with landing gear. As you come down,
begin to flair and hold it until touchdown. Once you
have touched down on the water, as the plane slows down,
begin to feed in up elevator as the plane settles. Once
you are slowed down, taxi back to shore and get ready for
another day at the lake.

13
Notes

14
GENERAL
1) I will not fly my model aircraft in sanctioned
events, air shows or model flying demonstrations until
it has been proven to be airworthy by having been
previously, successfully flight tested.
2) I will not fly my model higher than approximately
400 feet within 3 miles of an airport without notifying
the airport operator. I will give right-of-way and avoid
flying in the proximity of full-scale aircraft. Where
necessary, an observer shall be utilized to supervise
flying to avoid having models fly in the proximity of
full-scale aircraft.
3) Where established, I will abide by the safety rules
for the flying site I use, and I will not willfully and
deliberately fly my models in a careless, reckless and/
or dangerous manner.
4) The maximum takeoff weight of a model is 55
pounds, except models flown under Experimental
Aircraft rules.
5) I will not fly my model unless it is identified with
my name and address or AMA number, on or in the
model. (This does not apply to models while being
flown indoors.)
6) I will not operate models with metal-bladed
propellers or with gaseous boosts, in which gases
other than air enter their internal combustion
engine(s); nor will I operate models with extremely
hazardous fuels such as those containing
tetranitromethane or hydrazine.
7) I will not operate models with pyrotechnics (any
device that explodes, burns, or propels a projectile
of any kind) including, but not limited to, rockets,
explosive bombs dropped from models, smoke
bombs, all explosive gases (such as hydrogen-filled
balloons), or ground mounted devices launching a
projectile. The only exceptions permitted are rockets
flown in accordance with the National Model Rocketry
Safety Code or those permanently attached (as per
JATO use); also those items authorized for Air Show
Team use as defined by AST Advisory Committee
(document available from AMA HQ). In any case,
models using rocket motors as a primary means of
propulsion are limited to a maximum weight of 3.3
pounds and a G series motor. (A model aircraft is
defined as an aircraft with or without engine, not able
to carry a human being.)
8) I will not consume alcoholic beverages prior to,
nor during, participation in any model operations.
9) Children under 6 years old are only allowed
on the flight line as a pilot or while receiving
flight instruction.
RADIO CONTROL
1) I will have completed a successful radio equipment
ground range check before the first flight of a new or
repaired model.
2) I will not fly my model aircraft in the presence
of spectators until I become a qualified flier, unless
assisted by an experienced helper.
3) At all flying sites a straight or curved line(s) must
be established in front of which all flying takes place
with the other side for spectators. Only personnel
involved with flying the aircraft are allowed at or in
the front of the flight line. Intentional flying behind the
flight line is prohibited.
4) I will operate my model using only radio control
frequencies currently allowed by the Federal
Communications Commission. (Only properly
licensed Amateurs are authorized to operate
equipment on Amateur Band frequencies.)
2007 Official AMA
National Model Aircraft Safety Code

15
5) Flying sites separated by three miles or more
are considered safe from site-to site interference,
even when both sites use the same frequencies. Any
circumstances under three miles separation require
a frequency management arrangement, which may
be either an allocation of specific frequencies for
each site or testing to determine that freedom from
interference exists. Allocation plans or interference
test reports shall be signed by the parties involved
and provided to AMA Headquarters. Documents of
agreement and reports may exist between (1) two
or more AMA Chartered Clubs, (2) AMA clubs and
individual AMA members not associated with AMA
Clubs, or (3) two or more individual AMA members.
6) For Combat, distance between combat engagement
line and spectator line will be 500 feet per cubic
inch of engine displacement. (Example: .40 engine
= 200 feet.); electric motors will be based on
equivalent combustion engine size. Additional safety
requirements will be per the RC Combat section of the
current Competition Regulations.
7) At air shows or model flying demonstrations, a
single straight line must be established, one side of
which is for flying, with the other side for spectators.
8) With the exception of events flown under AMA
Competition rules, after launch, except for pilots or
helpers being used, no powered model may be flown
closer than 25 feet to any person.
9) Under no circumstances may a pilot or other
person touch a powered model in flight.
Organized RC Racing Event
10) An RC racing event, whether or not an AMA Rule
Book event, is one in which model aircraft compete
in flight over a prescribed course with the objective of
finishing the course faster to determine the winner.
A. In every organized racing event in which
contestants, callers and officials are on the course:
1. All officials, callers and contestants must properly
wear helmets, which are OSHA, DOT, ANSI, SNELL or
NOCSAE approved or comparable standard while on
the racecourse.
2. All officials will be off the course except for the
starter and their assistant.
3.”On the course” is defined to mean any area beyond
the pilot/staging area where actual flying takes place.
B. I will not fly my model aircraft in any organized
racing event which does not comply with paragraph A
above or which allows models over 20 pounds unless
that competition event is AMA sanctioned.
C. Distance from the pylon to the nearest spectator
(line) will be in accordance with the current
Competition Regulations under the RC Pylon Racing
section for the specific event pending two or three
pylon course layout.
11) RC night flying is limited to low-performance
models (less than 100 mph). The models must be
equipped with a lighting system that clearly defines
the aircraft’s position in the air at all times.
2007 Official AMA
National Model Aircraft Safety Code

© 2007 Horizon Hobby, Inc.
4105 Fieldstone Road
Champaign, Illinois 61822
[phone]
horizonhobby.com
10490