Hangar 9 Alpha Trainer User manual

Specifications
Wingspan: . . . . . . 63 in (1600 mm)
Length: . . . . . . . 52.5 in (1334 mm)
Wing Area: . 710 sq in (45.8 sq dm)
Weight: . . . . . 5–6 lb (2.27–2.72 kg)
ASSEMBLY MANUAL
Almost Ready-To-Fly

2
Table of Contents
Introduction ............................................................................ 2
Warning ............................................................................ 2
Contents of Kit.......................................................................... 3
Additional Required Equipment ................................................ 3
Additional Required Adhesives and Tools ................................ 4
Required Field Equipment ........................................................ 4
Other Items Needed .................................................................. 4
Section 1: Hinging the Ailerons ............................................ 5
Section 2: Joining the Wing Halves ...................................... 7
Section 3: Installing the Aileron Servo Tray .......................... 9
Section 4: Installing the Aileron Servo and Linkages .......... 11
Section 5: Installing the Landing Gear & Wheels ................ 13
Section 6: Installing the Horizontal and
Vertical Stabilizer................................................ 15
Section 7: Hinging the Elevator and Rudder ........................ 18
Section 8: Installing the Elevator and
Rudder Control Horns ........................................ 20
Section 9: Assembling the Fuel Tank .................................. 22
Section 10: Mounting the Engine .......................................... 24
Section 11: Installing the Radio System ................................25
Section 12: Installing the Rudder, Elevator and
Throttle Linkage.................................................. 27
Section 13: Installing the Spinner and Propeller .................. 30
Section 14: Balancing and Control Throw
Recommendations.............................................. 32
Preflight Checks at the Field .................................................. 33
Flying Your Alpha Trainer........................................................ 33
AMA Safety Code.................................................................... 34
Introduction
Congratulations on your purchase of the Hangar 9®Alpha Trainer
ARF (Almost Ready-To-Fly) kit. This aircraft was designed with
the beginning modeler in mind. It is an ideal trainer for the
novice pilot with gentle and forgiving flight characteristics. Once
you have some flight time under your belt, you can put your
Alpha through some basic aerobatics; rolls and loops are smooth
and graceful. The Alpha Trainer ARF kit also includes large
wheels to make ground handling easy, whether your flying field
has a paved runway or grass. And the Alpha Trainer ARF comes
out of the box 90% prebuilt and will have you out at the flying
field in only a few, short evenings.
Care has been taken to write a manual that will guide you
through the assembly of your aircraft. It is important to carefully
read through the instructions before beginning the assembly of
your aircraft. If you encounter difficulty in any construction
sequence, please feel free to contact one of our technicians—
we stand ready to provide any assistance we can concerning the
construction of your Hangar 9 Alpha Trainer ARF. Contact us at:
Horizon Hobby
4105 Fieldstone Road
Champaign, Illinois 61822
[phone]
www.horizonhobby.com
Warning
An R/C aircraft is not a toy; it can cause serious bodily harm
and damage to property. Fly only in open areas, preferably
AMA (Academy of Model Aeronautics) approved flying sites,
following all instructions included with your radio and engine.

3
Contents of Kit
Large Parts
a. Fuselage (HAN2452)
b. Wing Set with Joiner (HAN2451)
c. Tail Set (HAN2453)
d. Pushrods
e. Landing Gear Set (HAN2454)
Small Parts
1. Fuel Tank (HAN2479)
2. Engine Mount and Hardware
3. Wheel Collars
4. Clevises and Wire Keepers
5. Control Horns and Hardware
6. CA Hinges
7. Aileron Servo Mount
8. Decal Set (HAN2455) (not pictured)
Additional Required Equipment
• 4-channel radio (minimum)
• 4 standard servos (JRP5527)
• Engine .40–.48 2-cycle
.50–.72 4-cycle
• Standard 650mAh receiver battery
Recommended Radio Systems
• J-Line Quattro
• JR XF421
• JR XF631
• JR XP652
• JR XP662
• JR X-378
• JR XP8103
Recommended Engines
2-cycle
• Evolution Trainer Power System
• MDS™ .40 FS Pro
• MDS .48 FS Pro
• Webra™ .50GT
4-cycle
• Saito FA-50
• Saito FA-56
• Saito FA-65
• Saito FA-72
J-Line Quattro
Evolution Trainer
Power System
a
b
c
d
e
1
2
3
4
5
6
7

4
Additional Required Adhesives and Tools
Adhesives
• CA (cyanoacrylate) Glue: thick and thin
• CA remover/debonder
• 6-minute epoxy
• 30-minute epoxy
• Threadlock (Pacer Z42)
Tools
• Hobby knife w/#11 blade
• Drill
• Drill Bits: 1/16”
• Phillips screwdriver
• Pliers
Other
• Measuring device (e.g. ruler, tape measure)
• Straight edge
• Epoxy brushes
• Mixing sticks
• Rubbing alcohol
• Paper towels
• Wax paper
• Masking tape
• Felt-tipped pen/pencil
• RC foam
Required Field Equipment
The following are included in the Hangar 9®Start-Up Field Accessory pack (HANSTART)
• Sturdy cardboard construction tote box
• Manual fuel pump
• Two Hangar 9 glow plugs
• 4-way wrench
• Rechargeable glow driver with charger
• Chicken stick
Other Items Needed (Not included in Start-Up Field Accessory pack)
• Fuel, 10 to 15% nitro content (Cool Power or Powermaster recommended)
• Electric Starter w/12V battery (optional)

5
Section 1: Hinging the Ailerons
Parts Needed
• Right wing panel w/aileron
• Left wing panel w/aileron
• CA hinges (8)
Tools and Adhesives Needed
• Thin CA
• CA remover/debonder
• 6-minute epoxy
• Masking tape
• T-pins
• Rubbing alcohol
• Paper towels
Note: The photos and instructions in this section are for
the right wing panel. Repeat the same steps to hinge the
aileron on the left wing panel.
Step 1
Locate the right wing panel and remove the aileron. Note that the
leading edge of the aileron has a hole at one end that slides onto
the aileron torque rod already installed in the wing panel.
Step 2
Locate the CA hinges required for the aileron. Place a T-pin in the
center of each hinge and slide them into the precut hinge slots of
the wings trailing edge as shown.
Step 3
Trial fit the aileron to the wing; make sure there is no more than
1/32" gap along the hinge line. Once satisfied with the fit, remove
the aileron.
Step 4
Mix approximately 1/4 ounce of 6-minute epoxy. Using a tooth-
pick, apply the epoxy to the inside of the hole in the aileron. Slide
the aileron onto the torque rod and hinges, being careful not to
get any epoxy into the torque rod tube. Wipe away any excess
epoxy with rubbing alcohol and paper towels. Remove the T-pins
and push the aileron completely against the wing trailing edge.
Use masking tape to hold the aileron in place until the epoxy
completely cures.

6
Section 1: Hinging the Ailerons
Note: The hinges supplied with your Alpha™ Trainer ARF
are constructed of a special material that allows the thin
CA to “wick” or penetrate and distribute throughout the
hinge, securely bonding them to the wood structure. It is
important that you properly secure the hinges in place per
these instructions using high-quality thin CA glue.
Step 5
Once the epoxy has cured, check the aileron for freedom of
movement. Fully defect the aileron down and using thin CA
saturate each hinge. Turn the wing panel over and repeat the
process saturating the hinges again from the other side. Use
CA remover/debonder and a paper towel to remove any excess
CA along the hinge line.
Step 6
Hinge the opposite wing panel and aileron by repeating Steps 2–5.
Step 7
When the CA has completely dried, test the ailerons for security.
Firmly grasp the wing and aileron and using medium pressure try
to separate the aileron from the wing. Use caution not to crush the
wing structure.
Continued

Section 2: Joining the Wing Halves
7
Parts Needed
• Right and left wing halves
• Wing joiner
Tools and Adhesives Needed
• 30-minute epoxy
• Ruler
• Felt-tipped pen or pencil
• Rubbing alcohol
• Paper towels
• Wax paper
Step 1
Locate the wing joiner. Using a ruler and felt-tipped pen or pencil,
measure and mark the exact center of the joiner as shown.
Step 2
Trial fit the wing joiner into one of the wing panels. It should
insert smoothly up to the line marked in Step 1. If the fit is too
tight, it may be necessary to lightly sand the wing joiner. Carefully
slide the other wing panel onto the joiner until the two panels
meet. The wing panels should fit together with no gaps on either
the top or the bottom of the wing.
Step 3
Use masking tape to hold the wing halves together while you
check for the correct dihedral angle. Place the wing on a large flat
surface, with one wing panel resting flat on the surface the tip of
the opposite wing panel should be 5" from the flat surface. When
you are satisfied with the dihedral, separate the wings and remove
the joiner.
Note: Read through the remaining steps of this section
before proceeding to glue the wing panels together.
Hint: It is extremely important to use plenty of epoxy when
joining the wing panels together. It will also be helpful to
use wax paper under the wing center joint to avoid gluing
the wing to your worktop.
Step 4
Mix approximately 1 ounce of 30-minute epoxy. Using an epoxy
brush, apply a generous amount of epoxy to the wing joiner cavity
of one wing panel.
Step 5
Completely coat one half of the wing joiner with epoxy up to the
mark made in Step 1. Insert the epoxy coated side of the joiner
into the joiner cavity up to the mark.
5"

8
Section 2: Joining the Wing Halves
Continued
Step 6
Apply a generous amount of epoxy to the other wing panel
joiner cavity.
Step 7
Apply epoxy to the exposed portion of the wing joiner and to both
wing roots and carefully slide both wing panels together. Firmly
press both halves together allowing the epoxy to run out. Using
alcohol and paper towels, wipe off the excess epoxy. Check to
make sure there are no visible gaps between the two wing panels.
Step 8
Use masking tape to securely hold both wing halves together.
Place the wing assembly back onto the flat work surface (covered
with wax paper) and check the dihedral again as in Step 3.
Step 9
Double-check the wing center joint for any gaps and allow the
epoxy to cure.

9
Section 3: Installing the Aileron Servo Tray
Parts Needed
• Completed wing
• Plywood servo tray
• Wood servo rails
• Aileron servo w/mounting hardware
Tools and Adhesives Needed
• 6-minute epoxy
• Thick CA
• Hobby knife
Step 1
Locate the servo tray and two servo mount rails (3/8"x 2"). Using
thick CA, glue the servo rails to the servo tray as shown. The
beveled edge of the rails should form a “V” to allow the tray to
mount to the bottom of the wing. Allow the CA to dry.
Step 2
Install the mounting hardware (rubber grommets and brass eyelets)
supplied with your radio system on to the aileron servo.
Temporarily install the aileron servo on the servo tray as shown
and test fit the entire assembly to the wing. Make sure the servo
output shaft is oriented towards the trailing edge of the wing.
Note: It may be necessary to trim away some of the sheeting
on the bottom of the wing to allow the servo to slide down
into the opening. Using a sharp hobby knife, carefully
trim only a small amount at a time.

10
Section 3: Installing the Aileron Servo Tray
Continued
Step 3
Use a felt-tipped pen or pencil to trace the outline of servo tray
onto the bottom of the wing. Remove the servo and servo tray.
Using a sharp hobby knife, cut away the covering along the line
you just traced.
Caution: Only cut deep enough to cut the covering.
Do not cut into the wood sheeting underneath.
Step 4
Mix a small amount of 6-minute epoxy (approximately 1/4 ounce)
and coat both the bare wood of the wing and the servo tray rails.
Position the servo tray on the wing and secure it with masking
tape and allow the epoxy to fully cure.

11
Section 4: Installing the Aileron Servo
and Linkages
Parts Needed
• Wing assembly
• Aileron servo
• Aileron mounting screws (4)
• Aileron control wire (2)
• Nylon clevis w/keeper (2)
• Wire keeper (2)
• Nylon horn bracket (2)
Tools and Adhesives Needed
• Thin CA
• Drill
• Drill Bit: 1/16"
• Small Phillips screwdriver
• Pliers
• Felt-tipped pen
• Ruler
Step 1
Temporarily install the aileron servo into the wing oriented as
shown. Using a felt-tipped pen, mark the location of the servo
mounting screws. Remove the servo from the wing.
Step 2
Using a 1/16" drill bit, drill the four locations marked in the previous
step for the mounting screws. Drill all the way through the servo
tray and wing sheeting. To strengthen the screw holes, place a
drop of thin CA into each hole and allow the CA to dry.
Step 3
Install the aileron servo and secure it to the wing using the
mounting screws provided with your radio system. Use caution
when installing the screws as not to contact the servo wire.
Step 4
Locate the nylon horn brackets and thread them onto the aileron
torque rods until the torque rod just begins to come through the
bracket as shown.
Step 5
Locate the aileron control wires (2) and clevises with keepers (2).
Thread a clevis onto each wire a minimum of 12 turns and connect
the clevises to the aileron horn brackets.

12
Section 4: Installing the Aileron Servo
and Linkages
Continued
Step 6
Install an “X” servo arm onto the aileron servo as shown. You
should clip off the shorter arms so they will not interfere with the
control wires. Position the servo arm so it is parallel with the
trailing edge of the wing.
Step 7
Use masking tape to hold the ailerons in their neutral position,
(even with the wings trailing edge). With the aileron servo arm at
neutral (parallel to the trailing edge of the wing), lay the aileron
control wires across the outer most hole and mark the wire with a
felt-tipped pen.
Step 8
Remove the control wires you just marked and make a 90-degree
(“L”) bend at the mark. Cut off the excess wire 5/16" past the bend.
Step 9
Install the control wires back onto the horn brackets and slide the
L-bend of the wires into the servo arm. Secure the aileron control
wire L- bends with the wire keepers as shown.

13
Section 5: Installing the Landing Gear
and Wheels
Parts Needed
• Main landing gear wire (2)
• Nose landing gear wire
• 23/4" main wheel (2)
• 21/2" nose wheel
• Large wheel collar w/setscrew (6)
• Nylon nose wheel steering block w/arm
• Nylon landing gear strap w/1/2" wood screws
Tools and Adhesives Needed
• Threadlock
• Phillips screwdriver
• Drill
• Drill Bit: 1/16"
Step 1
Locate the main landing gear wires (2) hold down straps (2) and
mounting screws (4) provided in your kit.
Step 2
Locate the main landing gear mounting location on the underside
of the fuselage and insert the wires into the predrilled holes as
shown. Note that the wires lay side by side in the precut groove in
the landing gear block.
Step 3
Locate the mounting screw holes drilled on either side of the
landing gear wires. Secure the main landing gear wires using the
straps and the 1/2" wood screws provided with your model.
Step 4
Locate the two main wheels (23/4") and 4 wheel collars
w/setscrew. Slide a wheel collar onto each axle approximately 1"
and tighten the setscrew, next slide the wheel on and then another
wheel collar. Adjust the collars so that the wheel spins freely.
Note: Use Threadlock on each setscrew to prevent the
wheels from falling off in flight.

14
Section 5: Installing the Landing Gear
and Wheels
Continued
Step 5
Locate the nose wheel steering block. Mount the steering block to
the firewall of the fuselage as shown.
Step 6
Slide the nose gear wire through the steering block and steering
arm as shown and tighten the setscrew on the steering arm to
secure the nose gear. You want the setscrew to tighten against the
flat ground into the nose gear wire.
Step 7
Install the 21/2" nose wheel using two wheel collars as you did for
the main wheels in Step 6 centering the wheel on the axle.

15
Section 6: Installing the Horizontal and
Vertical Stabilizer
Parts Needed
• Fuselage assembly
• Wing assembly
• Horizontal stabilizer
• Vertical stabilizer
Tools and Adhesives Needed
• 30-minute epoxy
• Hobby knife
• 90-degree square
• Tape measure
• Masking tape
• Rubbing alcohol
• Paper towels
Step 1
Locate the horizontal stabilizer and elevator assembly and remove
the elevator. Use a felt-tipped pen/pencil and ruler to mark the
center of the stabilizer at the trailing edge as shown. Using a
triangle, extend the center mark forward to the leading edge of
the stabilizer. Make sure the line is 90 degrees to the trailing edge
of the stabilizer.
Step 2
Mark the center of the stabilizer saddle at the trailing edge of the
saddle as shown.
Step 3
Lay the horizontal stabilizer on the saddle and align the rear mark
of the stabilizer with the mark on the saddle. Align the front of the
stabilizer with in the middle of the opening for the vertical fin.
Once you are satisfied with the alignment, carefully place a couple
of T-pins through the stabilizer and the saddle.

16
Section 6: Installing the Horizontal and
Vertical Stabilizer
Continued
Step 4
With the horizontal stabilizer properly aligned, use a felt-tipped
pen or pencil to carefully mark the bottom of the stabilizer where
it meets the fuselage.
Step 5
Remove the stabilizer. Using a sharp hobby knife, carefully
remove the covering from the center of the stabilizer, cutting 1/8"
inside the lines you marked in the previous step. Use only enough
pressure to cut the covering and not the wood underneath, as doing
so will severely weaken the structure of the horizontal stabilizer.
Step 6
Before gluing the horizontal stabilizer in place, reposition the
stabilizer onto the stabilizer saddle. Use the lines drawn in Step 4
to reposition the stab correctly. Using a 90-degree square, make
sure the stabilizer is square to the fuselage as shown. Make any
adjustment needed by sanding the stabilizer saddle until the
proper alignment is achieved. Remove the horizontal stabilizer
from the fuselage.
Step 7
Mix at least 1/ 2 ounce of 30-minute epoxy and coat the horizontal
stabilizer saddle and stabilizer center section.
Step 8
Lay the horizontal stabilizer onto the saddle, lining up the center
mark of the stabilizer with the rear of the saddle and the opening
for the vertical fin. Wipe away any excess epoxy with rubbing
alcohol and paper towels.
Step 9
Use masking tape to hold the stabilizer in place as the epoxy
cures. Allow the glue to cure before moving on to Step 10.

17
Section 6: Installing the Horizontal and
Vertical Stabilizer
Continued
Step 10
Locate the vertical fin and rudder assembly. Remove the rudder
and test fit the vertical fin in place. Make sure the rear of the fin
sits flat on the forward portion of the stabilizer. Once satisfied, use
a felt-tipped pen to mark the fin where it inserts into the fuselage.
Also mark the top of the stabilizer where the fin contacts.
Step 11
Remove the fin and use a sharp hobby knife to remove the covering
where the fin inserts into the fuselage, cutting 1/16" inside the
lines you drew in the previous step. Also cut away the covering
on top of the horizontal stabilizer, 1/16" inside the lines. Use only
enough pressure to cut the covering not the wood underneath.
Re-install the fin into the fuselage to check the fit.
Step 12
Mix at least 1/2 ounce of 30-minute epoxy and coat the vertical
fin where it meets the fuselage and stabilizer. Also coat the fin slot
in the fuselage.
Step 13
Insert the fin into the fuselage and wipe away any excess epoxy
using rubbing alcohol and a paper towel. Make sure the fin is
90 degrees to the stabilizer as shown.
Step 14
Use masking tape to hold the fin in place as the epoxy cures.
Allow the epoxy to cure before hinging the rudder.

18
Section 7: Hinging the Elevator and Rudder
Parts Needed
• Fuselage assembly
• Elevator
• Rudder
• Hinges (7)
Tools and Adhesives Needed
•Thin CA
• CA remover/debonder
• T-pins
• Rubbing alcohol
• Paper towels
Caution: The hinges included with the Alpha™ Trainer
ARF are made of a special material that allows the thin
CA to “wick” or penetrate and distribute throughout the
hinge, securely bonding them to the wood structure. It is
imperative that you properly secure the hinges in place per
these instructions using high quality thin CA glue.
Step 1
Locate the four elevator hinges, place a T-pin in the center of each
hinge and slide them into the horizontal stabilizer until the T-pin
is snug against the trailing edge as shown.
Step 2
Install the elevator onto the hinges. Remove the T-pins and push
the elevator up against the stabilizer until there is only a slight
gap (1/32" or less) at the hinge line.
Step 3
Using high-quality thin CA glue, deflect the elevator down and
completely saturate each hinge.
Step 4
Turn the fuselage over and repeat the hinge-gluing process by
deflecting the elevator in the opposite direction and again
completely saturating each hinge with thin CA. Wipe away any
excess CA with CA remover/debonder and a paper towel. Allow
the CA to completely dry.
Step 5
Once the CA has dried, check the hinges for security by trying to
pull the elevator from the stabilizer. Use only slight pressure and
be sure not to crush the wood structure of the stabilizer or elevator.

19
Section 7: Hinging the Elevator and Rudder
Step 6
Install the three rudder hinges as you did for the elevator placing
a T-pin through the center of each hinge to keep it centered while
installing the rudder. Install the rudder and remove the T-pins and
push the rudder against fin until there is only a slight gap (1/32"
or less). Deflect the rudder in one direction and using high quality
thin CA glue completely saturate each hinge.
Step 7
Deflect the rudder in the opposite direction and again saturate
each hinge with thin CA. Using CA remover/debonder wipe off
any excess CA on the rudder hinge line. Allow the CA to dry.
Step 8
Once the CA has completely dried, check the rudder for security
by trying to pull the rudder from the fuselage. Use only enough
pressure to test for security and be careful not to damage the
wood structure of the rudder or fin.
Continued

20
Section 8: Installing the Elevator and
Rudder Control Horns
Parts Needed
• Fuselage assembly
• Control horn w/back plate (2)
• Mounting screws (6)
Tools and Adhesives Needed
• Drill
• Drill Bit: 1/16"
• Felt-tipped pen or pencil
Important: When installing the control horns, it’s
important that the holes in the control horns where the
pushrod attaches are directly in line with the control
surface hinge line.
Step 1
To locate the elevator control horn position, measure the center
bottom of the elevator. Mark the elevator as shown with a felt-
tipped pen or a pencil. This mark will be the center of the elevator
control horn location.
Step 2
Place the center of the control horn on the elevator at the mark
made in the previous step. Align the holes in the control with the
hinge line as noted above. Mark the mounting holes of the control
horn with a felt-tipped pen or pencil.
Step 3
Drill 1/16" holes through the elevator as marked. Make sure to
drill these holes parallel to each other to allow the back plate of
the horn to fit properly.
Step 4
Using the three screws and the back plate provided, attach the
elevator control horn and fasten in place with a Phillips screwdriver.