Hangar 9 46% TOC Ultimate 10-300 User manual

WE GET PEOPLE FLYING
TM
®
Specifications
Wingspan..........................................................................................100 in (2540 mm)
Length................................................................................................110 in (2794 mm)
WingArea.........................................................................................3310 sq in (213.5 sq dm)
Weight...............................................................................................40–44 lb (18–20 kg)
Engine.................................................................................................150–200cc gas engine
Radio..................................................................................................6-channel w/15 servos
ASSEMBLY MANUAL
46%
TOC Ultimate 10-300

Thank you for purchasing the Hangar 9®46% TOC Ultimate. Because size and weight of this model creates a
higher degree for potential danger, an added measure of care and responsibility is needed for both building and
flying this or any giant-scale model. It’s important that you carefully follow these instructions, especially those
regarding hinging and the section on flying.
Like all giant-scale aerobatic aircraft, the Hangar 9®TOC Ultimate requires powerful, heavy-duty servos. Servos
greatly affect the flight performance, feel and response of the model. To get the most out of your Ultimate, it’s
important to use accurate, powerful servos on all control surfaces. In the prototype models, we used JR 8411
digital servos with excellent results. A less powerful servo can lead to a crash. The Hangar 9®TOC Ultimate does
not include hardware. Many experienced giant-scale pilots have specific hardware preferences and can individually
choose the components they prefer.
Throughout the manual, we give hardware recommendations. If using another type/brand of hardware than
recommended, be sure that it’s strong enough for this application and properly installed. If you encounter difficulty
in any construction sequence, please contact one of our technicians. We can provide assistance concerning the
construction of your Hangar 9®46% TOC Ultimate 10-300.
Introduction
Additional Required Equipment
Radio Equipment
• 6-channel radio system (minimum)
• Receiver (JRPR955S or JRPR945S recommended or
equivalent) (1 or 2)
• 1 standard servo
(JRPS537 recommended or equivalent)
• 14 digital ultra torque servos
(JRSDS8411 recommended or equivalent)
• JR MatchBox™ (JRPA900) (5)
• JR Charge Switch (JRPA004) (3)
• 6" Aileron Extensions (JRPA095) (4)
• 12" Heavy-Duty Servo Extension (JRPA098) (6)
• 18" Heavy-Duty Servo Extension (JRPA099) (8)
• 24" Heavy-Duty Servo Extension (JRPA102) (6)
• Y-Harness (JRPA133) (2)
2
Recommended JR Systems
• JR XP8103 • PCM 10X Engine Requirement • 150–200cc gas engine

3
Additional Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Other Items Needed (not included in the kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Required Tools and Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Starting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 1: Aileron Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 2: Temporary Hinging of the Ailerons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 3: Aileron Control Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 4: Gluing the Aileron Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 5: Aileron Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 6: Hinging the Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 7: Hinging the Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 8: Sealing the Hinge Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 9: Elevator Control Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 10: Rudder Control Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 11: Mounting the Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 12: Mounting the Vertical Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Section 13: Elevator Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Section 14: Rudder Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Section 15: Tail Wire Bracing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Section 16: Tail Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 17: Main Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 18: Wheel Pant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Section 19: Cabane Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Section 20: Interplane Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Section 21: Bottom Wing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Section 22: Top Wing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Section 23: Interplane Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Section 24: Setting the Incidence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Section 25: Engine Box Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Section 26: Mounting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Section 27: Mounting the Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Section 28: Mounting the Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Section 29: Final Radio Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjusting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Control Throws and Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Preflight at the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Setup and Flight Information by Mike McConville . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2003 Official AMA National Model Aircraft Safety Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Table of Contents

Contents of Kit
4
A. HAN1101 Fuselage w/Hatch
B. HAN1102 Right TOP Wing w/Aileron
C. HAN1103 Left TOP Wing w/Aileron
D. HAN1104 Right BOTTOM Wing w/Ailerons
E. HAN1105 Left BOTTOM Wing w/Ailerons
F. HAN1106 Stabilizer w/Elevators
G. HAN1107 Fin/Rudder Set
H. HAN1108 Aluminum TOP Wing Tube
I. HAN1109 Aluminum BOTTOM Wing Tube
J. HAN1110 Canopy
K. HAN1111 Canopy Hatch
L. HAN1112 Painted Fiberglass Cowl
M. HAN1113 Fiberglass Wheel Pant Set
N. HAN1114 Carbon Fiber Landing Gear
O. HAN1115 Outer Wing Strut Set
P. HAN1116 Painted Aluminum Cabane
Strut Assembly
Q. HAN1117 Carbon Fiber Cabane Center Rib
R. HAN1118 Tail Fin Block
Warning
An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in open areas,
preferably at AMA (Academy of Model Aeronautics) approved flying sites, following all instructions included with your
radio and engine.
R
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
A

5
Additional Required Tools and Adhesives
Other Items Needed (not included in the kit)
• Propeller (consult your engines instruction manual)
• Large servo arm (JRPA212) (2)
• 6" Ultimate Spinner
• 4 1/2" Hangar 9 Pro-Lite Wheels (HAN309)
• 1 1/2" Hangar 9 Pro-Lite Wheel (HAN300)
• Tail Wheel Bracket
• 8-32 Control Horns (HAN3614) (12)
• 4-40 Ball Links (HAN3616) (30)
• 4-40 Double Ball Links (HAN3619) (6)
• 4-40 Full Servo arms (HAN3576) (4)
• Rudder bellcrank (optional)
• Elevator 3D Servo Arm (HAN3579) (2)
• Aileron Servo Arm (HAN3574) (8)
• Throttle Servo Arm (HAN3531)
• 4-40 x 3 1/2" Titanium Pro-Link (HAN3554) (10)
• 4-40 x 4" Titanium Pro-Link (HAN3555)
• 4-40 x 1 1/2" Titanium Pro-Link (HAN3550) (8)
• 50-ounce fuel tank
• Tygon fuel tubing
• Civilian pilot
Tools
• Canopy Scissors
• Clamps
• Drill
• Drill bit: #44, 1/16”, 1/2”, 1/8”, 11/64”, 3/16”.
3/32”, 5/16”, 5/32”, 5/64”, 9/64”
• Hex wrench set
• Hinging tool
• Incidence meter
• Phillips screwdriver
• Pro-Link Wrench (HAN3558)
• Razor saw
• Rotary tool w/sanding drum
• Ruler
• Scissors
• Socket wrench
• Square
• Tap handle
• Tap: 4-40, 8-32
• Tape measure
• Wrench
Other Required Items
• Mixing sticks for epoxy
• Epoxy brushes
• Denatured alcohol
• Sanding bar
• Sandpaper (medium)
• Paper towels
• Wax paper
• Felt-tipped pen or pencil
• Measuring device (e.g. ruler, tape measure)
• T-pins
• String
• Radio packing foam
Adhesives
• Thin CA (cyanoacrylate) glue
• Thick CA (cyanoacrylate) glue
• CA remover/debonder
• 6-minute epoxy
• 30-minute epoxy
• Pacer Z-42 Thread lock
• Canopy glue (R/C-56)
• Masking tape (3M blue recommended)

Before Starting Assembly
6
Using the Manual
Before beginning the assembly of the Ultimate, remove each part from its bag for inspection. Closely inspect
the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact
Horizon Product Support.
If any wrinkles in the covering, use a heat gun and covering iron to remove them. Use caution while working around
areas where the colors overlap to prevent separating the colors. Start with a low heat setting and gradually work up
to the optimum working temperature.
This manual is divided into sections to help make assembly easier to understand and to provide breaks between
each major section. Take your time and follow the directions.
Warranty Information
Horizon Hobby, Inc. guarantees this kit to be free from defects in both material and workmanship at the date of
purchase. This warranty does not cover any parts damaged by use or modification. In no case shall Horizon
Hobby's liability exceed the original cost of the purchased kit. Further, Horizon Hobby reserves the right to change
or modify this warranty without notice.
In that Horizon Hobby has no control over the final assembly or material used for the final assembly, no liability
shall be assumed nor accepted for any damage of the final user-assembled product. By the act of using the
product, the user accepts all resulting liability.
Once assembly of the model has been started, you must contact Horizon Hobby, Inc. directly regarding any
warranty question that you have. Please do not contact your local hobby shop regarding warranty issues, even if
that is where you purchased it. This will enable Horizon to better answer your questions and service you in the
event that you may need any assistance.
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.
Horizon Hobby
4105 Fieldstone Road
Champaign, Illinois 61822
[phone]
www.horizonhobby.com

Section 1: Aileron Servo Installation
7
Required Parts
• Top wing panels (left and right)
• Bottom wing panels (left and right)
• 24" Aileron Extensions (JRPA102) (4)
• 6" Aileron Extensions (JRPA095) (4)
• Servos w/mounting hardware (60 oz in minimum
torque) (8)
• Y-Harness (JRPA133)
• 1" Servo Arms (HAN3574-JR or
HAN3575-Futaba) (8)
Required Tools and Adhesives
• Hobby knife • Drill Bit: 1/16"
• Drill • Tap: 8-32
• Tap handle • Phillips screwdriver
• Thread or dental floss • Felt-tipped pen
Note: The ailerons require servos with a
minimum of 120 oz in of torque. We installed
JR 8411 digital servos for the ultimate in
precision control.
MatchBox Option: To simplify the
installation of the aileron servos, you may
want to use the JR™ MatchBox™ servo
matching/power system (JRPA900). Four
MatchBoxes would be used in this
application—one for each wing panel. The
MatchBox allows easy adjustment of the
servo’s center and endpoints, making aileron
setup a snap. You can also use a separate
battery to run the Matchbox, reducing the load
on the flight battery powering the receiver.
FAST FACTS: It is common to use two servos
per aileron on many larger models. This setup
requires some special attention to assure the
servos do not fight each other. If this is not
done correctly, battery consumption will be
greatly increased, and in the case of a high
torque digital servo, the servos may be
damaged. When setting up the ailerons with
two servos, there are some special steps that
need to be taken.
Step 1
Select two sets of servos and Hangar 9®1" arms that
have the same neutral. All servos will have a slightly
different neutral. If you are using Hangar 9 metal arms,
they don’t always orient the same, (i.e. the splines are not
oriented the same relative to the arm). First choose one
servo and arm, plug it into the aileron channel on your
receiver through the Y-connection and set to EXACT
NEUTRAL, (i.e. servo arm is perpendicular to the servo
centerline). Next, start plugging in your other servos one
by one and installing the arms until you find one that is
as close as you can get to the EXACT SAME NEUTRAL as
the other servo. Repeat this process to find a total of four
sets of servos. A MatchBox comes in handy here, as the
servos can be made to match, and the above steps can be
skipped.
Step 2
Install the servo hardware (grommets and eyelets)
included with the servos. Plug a 6" and 24" extension into
each of the sets of matched aileron servos.
Step 3
Use string, dental floss or a commercially available device
to secure the servo lead to the extension.

8
Section 1: Aileron Servo Installation
Note: It is always a good idea to secure the
servo connector and servo extension together
to prevent the wires from becoming unplugged
inside the wing.
Step 4
Tie a weight to a piece of string. A wheel collar works
great in this application. Lower the string into the wing
from the root. Let the weight drop out through the
opening for the servo.
Step 5
Insert the servo with the 24" extension towards the tip
of the wing. Use the string to pull the servo lead through
the wing. Position the servo so the output shaft is towards
the trailing edge of the wing. Use a 1/16" drill bit to drill
the locations for the servo screws.
Step 6
Secure the servo using the screws provided
with the servo.
Step 7
Plug a JR™ MatchBox™ into the servos for each wing
panel. The final installation of the servos and linkages
will be covered in a later section.

9
Section 2: Temporary Hinging of the Ailerons
Required Parts
• Hinges (16) • Top wing panel (2)
• Bottom wing panel (2) • Top aileron (2)
• Bottom aileron (2)
Required Tools and Adhesives
• Coarse sandpaper
Step 1
Locate the hinges. Lightly sand each end of the hinge
point using coarse sandpaper. This will improve the bond
of the epoxy to the hinge.
Step 2
Make sure the holes in the aileron and wing for the
hinges are clear of covering. Use a hobby knife to remove
the covering if necessary.
Step 3
Temporarily install all the hinges in the aileron. Check
the fit of the hinges between the wing and aileron.
Make sure the gap is as close as possible while making
sure the throws listed in the back of the manual can
still be achieved.
Note: Do not glue the hinges at this time. The
ailerons must be removed to drill the locations
for the control horns.

Section 3: Aileron Control Horn Installation
10
Required Parts
• Control horn screws (4)• Control horn nuts (4)
Required Tools and Adhesives
• Hobby knife • Drill Bit: 5/32” and 5/16”
• Drill • Tap: 8-32
• Tap handle • Phillips screwdriver
Step 1
Draw a line perpendicular to the trailing edge. The line
must align with the outer hole on the servo arm.
Step 2
Mark the location for the aileron control horn. The horn
is positioned as shown.
1/4"

11
Section 3: Aileron Control Horn Installation
Step 3
Remove the aileron from the wing panel. Drill a 5/32"
hole perpendicular to the work surface in the location
marked for the aileron control horn. The top of the aileron
will be resting flat on the work surface. This will angle the
horn slightly forward and align the clevis with the hinge
line when installed. It is highly recommended to use a
drill press to drill this hole.
Work Surface
Drill
Step 4
Tap the hole for the screw using an 8-32 tap.
Step 5
Thread the screw into the hole from the top of the
aileron. Trace around the head of the screw using
a felt-tipped pen.

12
Section 3: Aileron Control Horn Installation
Step 6
Remove the screw, then use a hobby knife, counter sink
bit, or 5/16” drill bit to taper the hole. This is done to
counter-sink the head of the screw into the aileron.
Step 7
Once the aileron has been counter-sunk, thread
the screw back into the aileron.
Step 8
Repeat Steps 1 through 7 for the remaining ailerons.

13
Section 4: Gluing the Aileron Hinges
Required Parts
• Hinges (16) • Top wing panel (2)
• Bottom wing panel (2) • Top aileron (2)
• Bottom aileron (2)
Required Tools and Adhesives
• 30-minute epoxy • Coarse sandpaper
• Syringe or toothpick • Small brush
• Masking tape • Paper towel
• Denatured alcohol
FAST FACTS: Properly hinging the control
surfaces on giant-scale models is vitally
important! Poorly installed hinges affect the
model’s precision and control response and
can also be dangerous. Each and every hinge
needs to be securely bonded in place in both
the flying surface and the control surface. The
hinge pivot points need to be exactly parallel to
each other and precisely located on the center
of the hinge line. We regularly use Robart
Super Hinge Points in all giant-scale aircraft.
They are easy to install, very strong and offer
smooth friction-free control. The Hangar 9®
Ultimate control surfaces are predrilled to use
Robart Super Hinge Points (ROB309).
Step 1
Mix 1 ounce of 30-minute epoxy. Using a glue syringe
or toothpick, place a sufficient amount of 30-minute
epoxy into the hinge pockets on the aileron. Install the
hinge points until the hinge point center is flush with
the leading edge of the aileron. Some epoxy should
ooze out of the pocket as the hinge is installed. If not,
remove the hinge and apply more epoxy. Wipe away
excess epoxy with Denatured alcohol. Recheck that
the center of the hinge point is flush and parallel with
the leading edge. Position the hinges at 90 degrees and
let the epoxy fully cure. The ailerons will be installed
after the epoxy is fully cured.
Photo for Step 1
Photo for Step 1
Photo for Step 1
Photo for Step 1

14
Section 4: Gluing the Aileron Hinges
Note: Be sure that the hinge pivot pins are
parallel and flush to the trailing edge. It’s
important to frequently mix a fresh batch of
30-minute epoxy in order to achieve good glue
joint penetration. If you notice the epoxy
becoming thicker, mix a new batch.
Step 2
Mix 1 ounce of 30-minute epoxy. Lightly coat each hinge
using an epoxy brush or mixing stick. Use a syringe or
toothpick to place a sufficient amount of epoxy in each
hinge pocket in the wing. Place the hinges in the same
positions to make the installation in the wing easier.
Step 3
Carefully slide the aileron onto the wing. Remove any
excess epoxy using a paper towel and Denatured alcohol.
Apply even pressure to avoid twisting the aileron and
damaging the hinge pockets or hinges.

15
Section 4: Gluing the Aileron Hinges
Step 4
Move the aileron up and down through its range
of movement. Check to make sure the hinge gap
is small as possible (1/32" average) yet still
achieves proper throw.
Step 5
Use masking tape to hold the aileron in position
while the epoxy cures.
Step 6
Repeat Steps 1 through 5 for the remaining ailerons.
Section 5: Aileron Linkage Installation
Required Parts
• Control horns (4) • Wing assembly
• 4-40 x 3-1/2” Pro-Links (HAN3554) (8)
• 4-40 ball links (DLR87) (8)
Required Tools and Adhesives
• Phillips screwdriver
• Pro-Link Wrench (HAN3558)
Step 1
Thread a clevis onto the inboard control horn screw
until the bottom of the clevis is 1/2" from the base
of the aileron.
Step 2
Install a 4-40 ball link five to six turns onto a 3 1/4" long
4-40 Pro-Link. Screw the opposite end of the linkage five
to six turns into a clevis that will attach to the swivel
control horn installed in the previous step.
Note: Hangar 9®Titanium Pro-Links feature
right-hand threads on one end and left-hand
threads on the other. This allows for easy,
accurate adjustment without disconnecting the
linkages. Consistently putting the right-hand
threads toward the servo arms on all servos
will prevent you from getting confused as to
which way to turn the Pro-Link to lengthen or
shorten the linkage. Hangar 9 also offers a
Pro-Link Wrench (HAN3558) to make
adjustments easier.

16
Section 5: Aileron Linkage Installation
Step 3
Attach the linkage to the swivel horn on the inboard servo
only with the bolt supplied. Adjust the linkage length until
the hole in the ball link aligns with the outer hole in the
servo arm when the aileron is neutral and the servo arm
is centered.
Step 4
Repeat Step 3 for the second linkage, but do not connect
it to the servo arm.
Step 5
Temporarily plug the servos into the receiver and set
the programming to get the aileron functioning
correctly. Center the control surface with the trailing
edge of the wing.
Step 6
Install the clevis on the outboard control horn. Thread
on the clevis until the clevis is the same distance from
the aileron hinge line as the inboard clevis.
Step 7
Deflect the ailerons stick to full right and hold it there.
The easiest way is to have your transmitter set to PCM:
hold and then turn off the transmitter. Hold the clevis on
the outboard servo up to the horn and note how the holes
align. Turn the transmitter on and hold full left aileron and
again note how the holes align. The holes have to line up
nearly perfectly. If they don’t line up perfectly, adjust the
horn length (distance out from the aileron) in or out a turn
and recheck. Repeat this process until it is nearly perfect
at full deflection in both stick directions and at neutral.
Step 8
Attach the swivel clevis to the horn with the
supplied screw.
Step 9
Once both linkages have been adjusted, secure the
servo arm to the servo using the screw provided
with the servo.
Step 10
Repeat Steps 1 through 9 for all servos.

17
Section 6: Hinging the Elevators
Required Parts
• Hinges (6) • Elevator (2)
• Stabilizer
Required Tools and Adhesives
• 30-minute epoxy • Toothpicks or small dowel
• Small brush • Masking tape
• Felt-tipped pen • Ruler
• Razor saw • Paper towel
• Denatured alcohol • Drill Bit: 1/16"
• Hobby knife or hinging tool
• Drill
Step 1
Locate the hinges for the elevator.
Step 2
Position the inner hinge near the fuselage so it is
centered 1 1/2" away from the fuselage. The outer
hinge near the tip of the elevator is centered 1" in
from the end of the stabilizer. Use a ruler to determine the
location of the center hinge. Measure the location on both
the stabilizer and elevator.
Step 3
Use a hobby knife or hinging tool to cut the slots
for the hinges in the stabilizer.
Photo for Step 2

18
Section 6: Hinging the Elevators
Step 4
Install the hinges in the stabilizer.
Step 5
Slide the elevators into position against the stabilizer. Use
a felt-tipped pen to accurately transfer the location of the
hinges onto the elevators.
Step 6
Mix 1/2 ounce of 30-minute epoxy. Apply the epoxy to
one side of a hinge. Slide the hinge into the elevator.
Clean up any excess epoxy from the hinge using
denatured alcohol and a paper towel. Allow the epoxy to
fully cure before continuing to the next step.
Step 7
Check the fit between the stabilizer and elevator. Adjust
the slots in the stabilizer if necessary. Once the fit is
satisfactory, mix 1/2 ounce of 30-minute epoxy and join
the elevators and stabilizer.
Photo for Step 6

Section 6: Hinging the Elevators
19
Step 8
Clean up any excess epoxy using a paper towel and
denatured alcohol.
Step 9
Mark locations at the hinges for pinning the hinge. Each
mark should be 1/8" inside of the edge of the hinge.
Perform this step for all six hinges on both
the elevators and stabilizer.
Step 10
Drill the locations for the pins using a 1/16" drill bit. Drill
from the bottom of the stabilizer and elevator through the
hinge but not through the top of the elevator or stabilizer.
Wrap a piece of tape around the drill bit as a depth gauge
to prevent drilling through.
Step 11
Cut the tapered portion off the tip of a round toothpick.
Place the toothpick (or small dowel) into the holes drilled.
Use a razor saw to trim the excess flush with the elevator
and stabilizer. Apply medium CA to secure the toothpicks
to the elevators and stabilizer

20
Section 7: Hinging the Rudder
Required Parts
• Hinges (5) • Rudder
• Fin
Required Tools and Adhesives
• 30-minute epoxy • Toothpicks or small dowel
• Small brush • Masking tape
• Felt-tipped pen • Ruler
• Razor saw • Paper towel
• Denatured alcohol • Drill Bit: 1/16"
• Hobby knife or hinging tool
• Drill
Step 1
Locate the hinges for the fin. Use a ruler to locate
the hinges evenly along the length of the fin. Use
a hinging tool or hobby knife to cut the slots for
the hinges in the fin.
Note: Make sure the lower fin post is included
when positioning the hinges.
Step 2
Slide the fin up against the rudder. Mark the locations of
the hinges on the rudder using a felt-tipped pen. Cut the
slots for the hinges in the rudder using a hinging tool or
hobby knife.
Note: Make sure to avoid placing the
lower hinge in the same location as the
rudder horn dowel.
Step 3
Trim the rudder slightly at the hinge locations. This
provides room for the center of the hinge to achieve
the maximum amount of rudder throw and to provide the
smallest gap between the rudder and fin.
Photo for Step 2