Hangar 9 Cap232 User manual

ALMOST READY-TO-FLY
PRE-BUILT
90
%
INSTRUCTION MANUAL
WE GET PEOPLE FLYING
TM
TM
Specifications
Wingspan: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73′′
Length:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 1/4′′
Wing Area:. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1031 sq. in.
Weight (Approx.):. . . . . . . . . . . . . . . . . . . 11–12 lbs.
Recommended Engines:1.08 –1.20 2-Stroke
1.20 –1.50 4-Stroke
• 90% pre-built
• Highest quality Du-Bro and Sullivan hardware included
• Pre-covered in genuine UltraCote®featuring Matt Chapman’s
full scale trim scheme
• Pre-finished fiberglass cowl and wheel pants

2
Table of Contents
Introduction 3
Warning 3
AdditionalEquipment Required 3
Toolsand SuppliesRequired 4
Contentsof Kit 5
Section1: Hingingthe Ailerons 6
Section2: Joiningthe WingHalves 8
Section3: Installingthe AileronServos 12
Section4: Installingthe AileronLinkages 14
Section5: Mountingthe Wingto theFuselage 16
Section6: Installingthe Tail(Vertical andHorizontal Stabilizer) 19
Section7: Hingingthe HorizontalStabilizer andElevator 22
Section8: Hingingthe Rudderand Installingthe TailWheel 23
Section9: Installingthe ControlHorns 25
Section10: Installingthe MainLanding Gear 28
Section11: Assemblingand Mountingthe WheelPants 29
Section12: Installingthe Engine 31
Section13: Assemblingand Installingthe FuelTank 32
Section14: Installingthe Radio 34
Section15: Installingthe ControlLinkages 36
Section16: Attachingthe Cowling 38
Section17: Attachingthe Canopy 40
Section18: Balancingthe CAP 41
Section19: ControlThrow Recommendations 41
Pre-Flightat theField 42
AMASafety Code 43

Introduction
Congratulationson yourpurchase ofone ofthe finestARFs tobe produced!The Hangar9 CAP232 isa high-performanceaircraft best
suitedfor themore experiencedflyer andmodeler. Althoughthis isan ARF(Almost-Ready-to-Fly) kit,it doeshave someconstruction
featuresthat canbe challengingfor anew modeler.If youencounter difficultyin anyconstruction sequence,please feelfree to contact
oneof ourtechnicians—we standready toprovide anyassistance wecan concerningthe constructionof yourCAP. Youcan contact
usat 217-355-9511.
Warning
AnR/C aircraftis nota toy!If misusedit cancause seriousbodily harmand damageto property.Fly onlyin openareas, preferably
AMA(Academy ofModel Aeronautics)approved flyingsites, followingall instructionsincluded withyour radioand engine.
Additional Equipment Required
Radio Equipment
4Channels (minimum)
5Standard Servos
Standard600–1000 mAh Receiver Battery Pack
Y-Harness(if anon-computer radiois used)
Engines
1.08-1.2 2-CycleEngines
1.20-1.50 4-CycleEngines
Recommended 2-Cycle Engines Recommended 4-Cycle Engines
Webra1.20 Saito 1.20- 1.50
Saito1.20GK -1.50GK
Parts
AileronExtension (2)(JRPA114, 12′′silver) Tru–Turn Adaptor(for appropriateengine)
3′′Tru–Turn Spinner(TRU3002) Dubro KwikFueler Valve
3
Recommended JR Systems
JRXF642
JRXP783
JRXP8103
PCM10SxII
Propeller
FuelFilter
Foamfor CushioningTank
FuelTubing

4
Tools and Supplies Required
Adhesives
ThinCA (cyanoacrylate)glue
ThickCA (cyanoacrylate)glue
6-minuteepoxy
12-minuteepoxy
30-minuteepoxy
BlueLocktite 242
Canopyglue (R/C56)
Silversolder (StayBrite)
Tools
Drill
Drillbits: 1/16′′,5/32′′, 1/4′′,1/8′′
Solderingiron
SmallPhillips screwdriver
MediumPhillips screwdriver
Z-bendpliers
Pliers
1/16′′hex wrench
Smallround file
Moto-Toolwith sandingdrum
Hobbyknife with#11 blade
Mixingstick
Epoxybrush
90-degreetriangle
Sandingstick (mediumor fine)
Mediumsandpaper
Maskingtape
Straightedge
Measuringdevice (e.g.,ruler, tapemeasure)
Scissors
Papertowels
Waxpaper
Rubbingalcohol
Felttipped pen
Optional Equipment
Radiopacking foam
Antennatube

5
Contents of Kit
Large Parts
A.Fuselage E. Horizontalstabilizer withelevators
B.Left winghalf withaileron F. Cowl
C.Right winghalf withaileron G. Wheelpants (2)
D.Vertical stabilizerwith rudder
Other Parts
1. Pushrod& accessories 6. Fueltank andhardware
2. 1/8′′plywood die-cutparts 7. Trim sheet
3. Mainlanding gear 8. Metalmotor mounts
4. Hardwarebag 9. Canopy
5. Wheels 10. Tailwheel

6
Note: Thecontrol surfaces,including theailerons, elevators
andrudder, arepre-hinged withthe hingesinstalled,
butthe hingesare not gluedin place.It isimperative
thatyou properlyadhere thehinges andailerons in
placeper thesteps thatfollow usinga highquality thin
CAglue.
Step 1. Carefully remove the aileron from one of the wing
panels.Note theposition ofthe hinges.The CAPcomes with
highquality CA-typehinges.
Step 2. Remove eachhinge fromthe wingpanel andplace a
t-pinin thecenter ofeach. Slideeach hingeinto thewing panel
untilthe t-pinis snugagainst thewing.
Step 3. Slide theaileron ontothe winguntil thereis onlya
slightgap. Thehinge isnow centeredon thewing paneland
aileron.Remove thet-pin andsnug theaileron againstthe wing
panel.This willensure thatthe hingesare centered.
Step 4. Deflect the aileron and completely saturate the hinge
withthin CAglue. Theaileron’s frontsurface shouldlightly
contactthe wingduring thisprocedure. Ideally,when thehinge
isglued inplace, a1/32′′ gapor lesswill bemaintained
throughoutthe lengthof theaileron. Thehinge isconstructed of
aspecial materialthat allowsthe CAto wickor penetrateand
distributethroughout thehinge, securelybonding itto thewood
structure.
Section 1. Hinging the Ailerons
• Rightwing panelwith aileronand hinges
• Leftwing panelwith aileronand hinges • Instantthin CAglue • CAremover/debonder
• Papertowels
• T-pin(one foreach hinge)
Parts Needed Tools and Adhesives Needed

7
Step 5. Turn the wing panel over and deflect the aileron in the
oppositedirection andfrom theopposite side.Apply thinCA
glueto eachaileron hinge,making surethat theCA penetrates
intoboth theaileron andthe wing.
Step 6. Using CA remover/debonder and a paper towel, remove
anyexcess CAglue thatmay haveaccumulated onthe wingor in
theaileron hingearea.
Step 7. Repeat this process with the other wing panel, securely
hingingthe aileronin place.
Step 8. After both ailerons are securely hinged, firmly grasp the
wingand aileronto checkthat thehinges aresecurely gluedand
cannotbe pulledout. Dothis byapplying mediumpressure,
tryingto separatethe aileronfrom thewing. Usecaution thatyou
donot crushthe wingstructure.
Note: Workthe aileronup anddown severaltimes to“work
in”the hingesand checkfor propermovement.
CONTINUED
Section 1. Hinging the Ailerons

8
Step 1. Locate the dihedral brace (also called the wing joiner).
Usingthe ruler,determine thecenter ofthe braceand markit
witha pencil.
Step 2. Trial fitthe dihedralbrace intoone ofthe wingpanels. It
shouldinsert smoothlyup tothe centerline markedin Step1.
Nowslide theother wingpanel ontothe dihedralbrace untilthe
wingpanels meet.If thefit isoverly tight,it maybe necessaryto
sandthe dihedralbrace.
Step 3. Check for the correct dihedral angle. Place the wing on
alarge, flatsurface withone wingpanel restingon theflat
surface.The oppositewing tipshould beat 3′′in heightfrom the
surface(see illustrationbelow). Ifnecessary, sandthe dihedral
braceuntil thisis achieved.There shouldbe nogaps inthe wing
center.
Step 4. To checkfor adequateclearance ofthe cowlbetween the
wing’sleading edgeand thefuselage, trialfit thewing together
andtemporarily installon thefuselage withthe cowlinstalled. If
theclearance isnot adequate,install theextra plywoodcenter
wingrib toprovide thenecessary clearance(see diagramat left).
• Right/leftwing panels
• Dihedralbrace
• Plywoodwing dowelplate
• Woodendowels
• Wingbolt plates
• Wingtrim tape(white)
• 30-minuteepoxy
• 6-minuteepoxy
• Epoxybrush
• Maskingtape
• Hobbyknife
• Rubbingalcohol
• Papertowels
• Waxpaper
• Ruler
• Pencil
• Mediumsandpaper
• Mixingstick
Parts Needed Tools and Adhesives Needed
Section 2: Joining the Wing Halves
3′′
Clearance Cowl
Wing
Fuselage

9
Step 5. Mix up approximately 1 ounce of 30-minute epoxy.
Note: Itis extremelyimportant touse plentyof epoxywhen
joiningthe winghalves.
Step 6. Using a scrap piece of wood or an epoxy brush, smear a
generousamount ofepoxy intothe wingdihedral bracecavity in
onewing panel.
Step 7. Coat one half of the dihedral brace with epoxy up to the
pencilline drawnin Step1. Notethe orientationof thewing
brace— the“V” pointsto thetop ofthe wing,or facesup. Install
theepoxy-coated sideof thedihedral braceinto thewing joint
cavityof thewing half,up tothe centerline, makingsure the“V”
sideof thedihedral braceis orientatedcorrectly.
photo4-6B
Step 8. Apply a generous amount of epoxy into the wing brace
cavityof theother wingpanel.
Note: Youwill needto mixup additionalepoxy tocomplete
thejoining process.
Step 9. Now apply epoxy to all sides of the exposed area of the
dihedralbrace anduniformly coatboth wingroots withepoxy.
CONTINUED
Section 2: Joining the Wing Halves

10
Step 10. Carefully slide the two wing halves together and firmly
pressthem together,allowing theexcess epoxyto runout. There
shouldnot beany gapin thewing halves.Use rubbingalcohol
anda papertowel toclean upany excessepoxy.
Step 11. Apply masking tape at the wing joint to hold the wing
halvestogether securely.Place thewing ona flatsurface. With
onewing panellying flaton thesurface, theopposite wingtip
shouldbe proppedup soit is3′′ fromthe surface.Apply more
maskingtape tothe centerwing jointand recheckthe 3′′
measurement.Allow thewing jointto dryovernight.
Note: Itis helpfulto usewax paperunderneath thewing
centerwhile theepoxy iscuring sothe excessepoxy
doesnot adhereto thework area’ssurface.
Step 12. Allow the wing center joint to completely cure, then
removethe maskingtape.
Step 13. Locate the plywood wing dowel plate and use 6-
minuteepoxy toepoxy itin placeon thefront ofthe wing.When
installingthe plywooddowel plate,care shouldbe givento line
upthe holesin thewing andthe plateas closelyas possible.The
holeswill needto betrimmed outto allowthe dowelsto fit.
Step 14. Using 6-minute epoxy, epoxy the two wood dowels in
placesuch that1/2′′ isexposed.
CONTINUED
Section 2: Joining the Wing Halves
plywoodwing dowelplate

11
Step 15. After the wing dowels and plywood wing dowel plate
havedried, youcan mountthe twowhite coveredwing bolt
plates.
Note: Thecovering willhave tobe trimmedaway fromthe
areaof thebottom ofthe wingso thepieces canbe
epoxiedto thewing.
Trialfit thepieces, markingtheir location.Use asharp hobby
knifeto trimaway thecovering.
Caution: Becareful notto cutinto thewood asthis will
weakenthe structure.
Step 16. Mix up 1 ounce of 6-minute epoxy and epoxy the wing
boltplates tothe bottomof thewing. Thewing boltplate holes
willbe drilledout inSection 5.
Step 17. Locatethe whiteandteal wingcenter tapes. Applya
portionto thebottomof thewing after theepoxy hascured from
Step15.
CONTINUED
Section 2: Joining the Wing Halves

12
Step 1. Locate the servo opening in one of the wing halves.
Installthe recommendedservo hardwaresupplied withyour
radiosystem ontoyour servos(grommets andeyelets). Installa
servoextension leadto theservo aswell (a12′′ extensionis
recommended).Secure theconnectors witheither maskingtape
ora commercialconnector thatprevents theservo connectors
frombecoming disconnected.
Hint: It’salways agood ideato tapethe servoconnections
andextension togetherto preventthe wiresfrom
becomingunplugged inthe wing.
Step 2. Trial fit the servo into the servo opening. Some
trimmingmay berequired, dependingon thetype ofservo
installed.
Step 3. With the servo in place, mark the location of the servo
screwsthat areused tomount theservo tothe plywoodrail
insidethe servoopening inthe wing.
Step 4. Using a 1/16′′ drill bit, drill the servo screw locations
markedin theprevious step.
• Left/rightwing halves
• Standardsize servos(2)
• Servoextension(s) —(12′′ recommended)(2)
• Musicwire (36′′)
• Y-harness(if usinga non-computerradio)
• Hobbyknife
• Phillipsscrewdriver (medium)
• Drill
• 1/16′′ drillbit
• Maskingtape
• Pencilor felttipped pen
• Needlenose pliers
Parts Needed Tools and Adhesives Needed
Section 3: Installing the Aileron Servos

13
Step 5. Before mounting the servo, it would be wise to run the
servolead andextension throughthe wingand outthe opening
providednear thewing center.The servolead exitis locatedon
thetop ofthe wing.Turn thewing halfover andlook carefullyfor
asquare openingnear thecenter ofthe wingclose towhere the
wingjoiner slotis. Youwill haveto trimaway thecovering to
exposethe opening.Using asharp hobbyknife, removethe
coveringover theopening.
Step 6. Usinga smalldiameter piece ofmusic wire(36′′),thread
themusic wirethroughthe servoopening. You willhave toguide
thewire asyouthread itthrough the wingopenings. Usecare to
makesure youdonot crushany of thewing structure.Once you
seethe endofthe musicwire, a needlenose plierscan be usedto
graspthe wireandpull itout of theopening.
Step 7. Once you have the music wire threaded through the
wing,make asmall hookon oneend andtape itto oneend ofthe
servowire/extension. Carefullythread thewire andlead through
thewing.
Step 8. To prevent the lead from falling back inside the wing,
usemasking tapeto temporarilyhold itin placeby tapingthe
leadto thewing top.
Step 9. Repeat the procedure for the other wing half.
Note: Ifusing anon-computer radio,it willbe necessaryto
usea Y-harnessto connectboth aileronservos tothe
aileronchannel.
CONTINUED
Section 3: Installing the Aileron Servos

14
Step 1. For this assembly, you will be using a short (4”)
threadedrod, twoclevis anda regularand reversecontrol horn.
Usethe 4/40nuts aslocking devicesto keepthe clevisfrom
turning.There isalso alocking clipthat keepsthe clevisfrom
opening.The reversecontrol hornhas an“R” markedon its
base;the standardhorn hasno marking.For illustration
purposes,we willdescribe thehookup ofthe linkageon theright
wingpanel.
Step 2. Thread a 4/40 nut and clevis on each end of the
threadedrod. Nextlocate thestandard horn.The mountinghole
plateshould pointtoward thewing center.The linkassembly
goeson theouter servoarm orthe onepointing tothe wingtip.
Step 3. To establish the length needed, trial fit the horn and
linkageto theservo arm.Adjustments inlength aremade by
screwingone orboth clevisin orout. Thecontrol hornshould be
positionedso theholes areover thecenter lineof thehinge line.
Step 4. Once satisfied with the horn location (it should be a
straightline fromthe servoarm tothe horn),mark thelocation
witha felttipped pen.You willnote theservo ispositioned atan
angleto thewing, butis 90degrees tothe aileronhinge line.
Section 4: Installing the Aileron Linkage
• Wingassembly fromSection 2
• Leftcontrol horn
• Right(reversed) controlhorn
• Plasticplate (2)
• Screws(8)
• Short(4′′) threadedrod (bothends) (2)
• Clevis(4)
• 4/40nuts (4)
• MediumPhillips screwdriver
• Drill
• Drillbits: 1/16′′, 3/32′′
• Felttipped pen
• Moto-Tool
Parts Needed Tools and Adhesives Needed

15
Step 5. Using a 3/32′′ drill bit, drill the screw holes for
mountingthe controlhorn. Sincethe aileronbalsa issoft, we
recommendapplying thinCA intothe aileronthrough thedrilled
holesto saturateand stiffenthe balsain themounting area.
Step 6. Attach the control horn to the aileron using four screws
andthe plasticplate. Becareful notto accidentallypuncture the
coveringwith thescrewdriver.
Step 7. Repeat the process for the other aileron on the other
wingpanel
Note: Thecontrol hornmounting screwsmay beexcessively
longon somecontrol surfaces,and youmay wishto
cutoff theexcess lengthusing aMoto-Tool, leavinga
minimumof 1/8′′ ofmounting screwabove theplastic
plate.
CONTINUED
Section 4: Installing the Aileron Linkage

16
Step 1. Insert thewing intothe fuselageso thatthe wingdowels
projectinto theopen area(holes) inthe fuselagebottom. The
wingdowel supportsare thenslipped inplace onthe dowelsby
puttingthem onthrough thefuel tankcompartment.
Step 2. Center the wing so that the same space is on each side
ofthe fuselagebetween theforward wingsection andthe sideof
thefuselage. Equalthickness spacerscan betemporarily putin
thesespaces tomake surethe spacingis maintained.
Step 3. The wing dowel supports are lightly tack glued in place
byapplying asmall amountof epoxyor thickCA toa coupleof
placesalong thetop edgeof thewing dowelsupports. Thiswill
haveto bedone byreaching throughthe fueltank compartment.
Step 4. After the glue has dried, the wing can be removed and
thewing dowelsupports’ exactlocation canbe markedby
drawingalignment marksfrom thebulkhead ontothe dowel
supportsfrom insidethe wingcompartment.
Step 5. Remove the wing dowel supports by breaking them
loosefrom thetack gluing(be carefulnot tomix themup). Mix
up1/2 oz.of 12-minuteepoxy andglue thewing dowelsupports
inplace. Allowthe epoxyto curecompletely beforeattempting
thenext steps.
Step 6. After the epoxy has cured, you are ready to install the
winghold-down bolts.
• Wing
• Fuselage
• Plywoodwing dowelsupports (2)
• Winghold downhardware
• 30-minuteepoxy
• 12-minuteepoxy
• Epoxybrush
• Rubbingalcohol
• Papertowels
• Mixingsticks
• Felttipped penor pencil
Parts Needed Tools and Adhesives Needed
Section 5: Mounting the Wing to the Fuselage
• Pliers
• Ruler
• Drill
•1/4′′drill bit
• Roundfile

17
Step 7. Press the blind nuts into position below the rear wing
hold-downblock inthe rearportion ofthe fuselagewing area.
Usepliers withan adjustableopening tosqueeze theblind nuts
sothe “teeth”penetrate thewood andstay inplace.
Note: Itis importantthat theblind nutsbe fullypressed in
againstthe bottomof thewing hold-downblock to
makesure theyare properlyaligned. Thissets the
alignmentangle ofthe wingbolts.
Note: It’sa goodidea toplace apiece ofwood onthe top
sideof thewing bolthold-down blockto keepfrom
crushingthe wood.
Afteryou’re aresatisfied thewing blindnuts arein place,you
maywant toapply epoxyor CAto theblind nutsto
keepthem inplace. Donot epoxy orCA theinner
threads.
Step 8. Thread the wing hold-down bolts into the bottom side of
theblind nutsso theends ofthe boltsextend 1/8′′above the
wingseat.
Step 9. Carefully fit the wing into position on the fuselage,
slidingthe leadingedge dowelsinto thefuselage frontwing
dowelsupport bulkhead.
Step 10. Before drilling the wing hold-down bolt holes, check
thewing alignmentby measuringfrom eachwing tipto thetail of
thefuselage. Besure touse thesame pointon eachwing tip
exactlythe samedistance oneach sidefrom thecenter ofthe
wing.Use apoint atthe tailof thefuselage bottomat theexact
center.
CONTINUED
Section 5: Mounting the Wing to the Fuselage

18
Step 11. Once you’re satisfied with the alignment, press down
slightlybut firmlyon therear sectionof thewing. Theprotruding
wingbolts willmake anindentation inthe topwing covering.By
comparingthe wingtop andwing bottomyou cansee theslight
anglerequired whendrilling theholes inthe wingfor thewing
hold-downbolts.
Step 12. Using a 1/4′′drill bit,drill theexact centerof thewing
indentationson thetop ofthe wing,through thewing andwing
boltplates. Usespecial careto notethe angleof thebolts and
transferthat angleinto theholes beingdrilled.
Step 13. Trial fit the wing into position on the fuselage. Thread
thewing hold-downbolts intothe wingand looselytighten.
Checkthe alignmentof thewing bymeasuring thealignment as
youdid inStep 10.It maybe necessaryto slightlyenlarge the
holeswith asmall roundfile toobtain properalignment.
CONTINUED
Section 5: Mounting the Wing to the Fuselage

19
Step 1. On the rear of the fuselage, slots are pre-cut in the wood
structurefor thehorizontal stabilizerand thevertical stabilizer.
Youwill needto trimaway thecovering witha sharphobby knife.
Step 2. We will begin with mounting the horizontal stabilizer
first.Remove theelevators and,using aruler, locatethe center
lineof thehorizontal stabilizer.This linewill serveas areference
linewhen installingthe horizontalstabilizer onthe fuselage.
Step 3. Slide the horizontal stabilizer carefully into the slot
providedin thefuselage. Youmay haveto trimthe openingto
allowthe horizontalstabilizer tobe inserted.By notingthe center
lineyou marked,position thehorizontal stabilizerso thatit’s
centeredin thefuselage.
Step 4. Locate the center line of the fuselage and put a reference
markthere. Then,using along straightedge, measurefrom the
referencepoint onthe fuselageto thetip ofthe horizontal
stabilizer.Adjust thestabilizer positionuntil bothright andleft
measurementsare thesame.
Nowyou caninstall thewing andsight thehorizontal stabilizer
alignmentfrom therear ofthe aircraft.Make surethe horizontal
stabilizeris levelwith referenceto thewing.
• Fuselage
• Wing
• Horizontalstabilizer withelevators
• Verticalstabilizer withrudder
• Instantthin CAglue
• CAremover/debonder
• 30-minuteepoxy
• Epoxybrush
• Hobbyknife with#11 blade
• Straightedge
• Pencil
• Felttipped pen
• Maskingtape
Parts Needed Tools and Adhesives Needed
Section 6: Installing the Tail
• Rubbingalcohol
• Papertowels
• 90-degreetriangle
• Ruler

20
Step 5. Trial fit the vertical fin in position. Make sure the fin is
insertedcompletely. Someslight trimmingto thebottom ofthe
finmay berequired. Carefullycheck thefin tobe sureit’s aligned
90degrees tothe horizontalstabilizer. A90-degree triangleis
helpfulin thisstep.
Hint: Wheninstalling thevertical fin,use therudder to
checkfor properfin height.It maybe necessaryto cut
offa smallamount fromthe bottomof thefin toget the
rudderto dropdown tothe properposition sothe trim
betweenthe rudderand andfuselage willline up.
Step 6. Double check the horizontal stabilizer and vertical fin
alignment.It maybe necessaryto slightlytrim thebalsa woodon
thefuselage orfin witha sharphobby knifeto achieveexact
alignment.
Step 7. When you're satisfied with the alignment, carefully mark
theposition witha pencilat thejunction wherethe horizontal
stabilizermeets thefuselage topand bottomand wherethe
verticalfin meetsthe fuselage.The pencilshould makea light
indentationin thecovering.
Step 8. Remove the horizontal stabilizer and vertical fin and
carefullycut awaythe coveringwith asharp hobbyknife. Cut
approximately1/8′′ insidethe lineof thehorizontal stabilizerso
thatwhen thestab isrepositioned inplace, nobare woodshows.
Onthe verticalfin, cutthe coveringaway fromthe bottomof the
finand 1/8′′from thereference linemarked withthe pencil.
Again,make sureno barewood showswhen thefin is
repositioned.
CONTINUED
Section 6: Installing the Tail