Hangar 9 P-47D-40 Thunderbolt 30cc ARF User manual

P-47D-40 Thunderbolt 30cc ARF
Assembly Manual

2 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
WARNING: Read the ENTIRE instruction manual to
become familiar with the features of the product before
operating. Failure to operate the product correctly can result
in damage to the product, personal property and cause
serious injury.
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.
Do not attempt disassembly, use with incompatible
components or augment product in any way without the
approval of Horizon Hobby, Inc. This 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 serious injury.
Introduction
Few subjects are as magnificent in giant-scale as the mighty
P-47D Thunderbolt (aka The Jug). Its big, round-cowl
nose, stout airframe and wide stance landing gear make
for an imposing presence on any flight line. Now you can
experience the thrill of owning and flying a giant-scale Jug
without spending months at a workbench to do so.
The new Hangar 9®P-47D-40 Thunderbolt 30cc ARF comes
assembled and covered with an authentic UltraCote®trim
scheme. It also includes a huge list of additional details like
functional flaps, wing guns, a dummy radial engine and a
painted fiberglass cowl with hidden mounting screws. Three
different sets of decals give you your choice of markings.
You even have the option of adding extra scale details like
a full-depth cockpit, Robart retracts and a retractable tail
wheel, all of which are sold separately.
Putting together a beautiful giant-scale warbird really doesn’t
get much easier than this.
Product Support
For technical assistance with this product, please contact the
appropriate Horizon Product Support office. This information
is located in the back of this manual.
Specications
Wingspan 81.25 in (2.1m)
Wing Area 1164 sq in.(75.1 sq dm)
Fuselage Length 71 in (1.8m)
Weight Range 16.0 lb–19.0 lb (7.30–8.60 kg)
Engine/Motor Size: 2-stroke 26–40cc Gas
4-stroke 30–36cc Gas
4-stroke 1.80–2.20 Glow
EP Power 160 with
EFLB50005S30 (2)
Radio 6+ channel with 8 servos
(7 servos for EP)
Notice
All instructions, warranties and other collateral
documents are subject to change at the sole discretion
of Horizon Hobby, Inc. For up-to-date product
literature, visit http://www.horizonhobby.com and click
on the support tab for this product.
Meaning of Special Language
The following terms are used throughout the product
literature to indicate various levels of potential harm
when operating this product:
NOTICE: Procedures, which if not properly followed,
create a possibility of physical property damage AND a
little or no possibility of injury.
CAUTION: Procedures, which if not properly followed,
create the probability of physical property damage AND a
possibility of serious injury.
WARNING: Procedures, which if not properly followed,
create the probability of property damage, collateral
damage, and serious injury OR create a high probability
of superficial injury.
Table of Contents
Using the Manual..............................................................5
UltraCote® Covering Colors .............................................5
Recommended Power Setups...........................................5
Optional Retracts ..............................................................5
Transmitter Requirements.................................................6
Radio Equipment Requirements .......................................6
Optional Equipment ..........................................................6
Field Equipment Required.................................................6
Optional Field Equipment..................................................6
Required Adhesives ..........................................................6
Hardware/Accessory Sizes................................................6
Required Tools..................................................................6
Before Starting Assembly .................................................7
Binding the Radio System ................................................7
Aileron and Flap Installation..............................................7
Aileron and Flap Servo Linkage Installation ......................9
Fixed Main Gear Installation............................................12
Optional Retractable Main Gear Installation....................14
Rudder Installation..........................................................17
Fixed Tail Wheel Installation............................................18
Retractable Tail Wheel Installation ..................................21
Rudder and Tail Wheel Linkage Installation ....................23
Stabilizer and Elevator Installation ..................................25
Elevator Linkage Installation ...........................................28
Optional Electric Motor Installation.................................29
Gas Engine Installation ...................................................31
Fuel Tank Installation ......................................................33
Dummy Radial, Muffler and Cowling Installation............35
Retract Servo Installation................................................37
Receiver, Receiver Battery and
Switch Harness Installation .....................................39
Canopy Installation .........................................................41
Canopy and Basic Interior Installation ............................41
Optional Cockpit Kit Installation......................................42
Accessory Installation.....................................................43
Wing Installation.............................................................45
Decal Installation ............................................................46
Center of Gravity.............................................................48
Control Throws ...............................................................48
Before your first flight.....................................................49
Preflight ..........................................................................50
Range Test Your Radio ...................................................50
Safety Do’s and Don’ts for Pilots ....................................50
Daily Flight Checks..........................................................50
Limited Warranty ............................................................50
Warranty Services...........................................................51
Compliance Information for the European Union............52
Academy of Model Aeronautics
National Model Aircraft Safety Code........................52

3Hangar 9 P-47D-40 Thunderbolt 30cc ARF
Included Parts Listing
ITEM QTY USE
Fuselage with mounted hatch 1
Canopy 1
Wing panels with servo covers 4
Ailerons 2
Flaps 2
Stabilizer 2
Elevators 2
Rudder 1
Cowling 1
Wing tube 1
Stabilizer tube 1
Fuel tank 1
BAG 1
Landing gear cover, inner 2 Main wheel
Landing gear cover, outer 2 Main wheel
Plastic silver louver 2 Engine exhaust
Plastic silver scoop 1 Lower turbo charger exhaust
Plastic hatch cover 1 Tail wheel cover
Molded plastic silver mast 1 Top of fuselage antenna mast
8mm x 100mm silver tube 1 Wing tip pitot tube
BAG 2
67mm x 138mm plywood plate 1 Tank cover
90mm x 60mm plywood plate 1 Receiver mount
Hook and loop straps 20mm x 250mm 2 Receiver and Battery
154mm x 100mm drill guides 3 Firewall drilling guides
BAG 3
3mm tail wheel wire 1
13/4-inch tail wheel 1
Nylon tail wheel support mount 1 Fixed tail wheel mount
Nylon tail wheel support bracket 1 Fixed tail wheel bracket
Metal steering arm with setscrew 1 Fixed tail wheel steering arm
M3 wheel collar with setscrew 4 Tail wheel and tail wire support
4-40 x 1/2-inch socket head screw 6 Tail wheel mount
#4 flat washer 6 Tail wheel mount
BAG 4
6mm x 80mm silver aluminum tube 2 Machine gun
6mm x 60mm silver aluminum tube 2 Machine gun
6mm x 40mm silver aluminum tube 2 Machine gun
6mm x 20mm silver aluminum tube 2 Machine gun
1/2-inch x 13-inch black aluminum tube 1 Stabilizer tube
1/4-inch x 3-inch black aluminum tube 2 Stabilizer ant rotation tube
BAG 5
Hinge point 6 Flaps
Control horn 5 Aileron (2) Elevator (2) Rudder (1)
1/4-20 x 2-inch nylon bolt 2 Wing attachment
CA hinges 17 Aileron (6) Elevator (8) Rudder (3)
Clevis keepers 14 Aileron (4) Flap (4) Elevator (4) Rudder 2)
BAG 6
M2.5 x 10 screw 24 Servo cover Aileron (12), Flap (12)
M2.5 x 10 screw 15 Control horn Aileron (6), Elevator (6) Rudder (3)
M2.5 x 10 screw 5 Tail wheel cover (5)
4-40 x 1/2-inch socket head screw 6 Receiver mount (4), cockpit tub (2)
4-40 x 5/8-inch socket head screw 6 Cowl
#4 flat washer (black) 12 Cowl (6), receiver mount(4),cockpit (2)
8-32 x 11/4-inch machine screw 4 Engine to engine mount
8-32 x 1-inch machine screw 4 Engine mount to firewall
8-32 lock nut 4 Engine to engine mount
8-32 blind nut 4 Engine to firewall
#8 flat washer 8 Engine bolts
BAG 7
4-40 metal clevis 14 Aileron (4), Flap (4), Rudder (2), Elevator (4)
2mm x 2-56 ball link 1 Carburetor arm
Pushrod connector with nylon retainer 1 Throttle pushrod to servo arm
M3 x 4 setscrew 1 Throttle
4-40 nut 14 Aileron (4) Flap (4) Elevator (4) Rudder (2)
4-40 x 76mm threaded pushrod 2 Aileron (2)
4-40 x 52mm threaded pushrod 2 Flap (2)
2-56 x 375mm threaded one end 1 Throttle
4-40 x 1135mm threaded pushrod 2 Elevator
4-40 x 1115mm threaded pushrod 1 Rudder
4-40 x 303/16 threaded pushrod 1 Tail wheel mechanical retract
8-inch Pushrod housing 1 Throttle
BAG 8
Braided cable 1 Tail wheel steering
Copper tubing crimp 4 Steering cable
4-40 threaded eyelet 2 Steering cable
Wire eyelet 2 Steering cable to servo arm
4-40 metal clevis 2 Steering cable
4-40 nut 2
Pushrod connector with nylon retainer 2 Rudder cable to servo arm
M3 x 4 setscrew 1 Rudder

4 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
Contents of Kit and Parts Listing
BAG 9
6mm wire strut 2 Fixed main landing gear
Metal mounts 2 Fixed landing gear mounting
base
4mm setscrew 2 Wire strut to mounting base
6mm wheel collars with setscrew 4 Main wheel to strut
Allen wrench, 2mm 1
6/32 x 1-inch socket head screw 8 Landing gear
6mm plywood bracket 4 Landing gear door to fixed
gear
MISCELLANEOUS
22oz (650cc) fuel tank, unassembled 1
Plastic cap 1
Metal disc 1
M3 x 20 screw 1
Metal clunk 1
Copper tubing 2
Aluminum motor mount (left and right) 2
11/4-inch x 293/8-inch anodized tube 1 Main wing tube
51/8-inch (130mm) scale wheel 2
Painted dummy engine and crankcase 1
3mm plywood assembled tray 1 Retract valve mount
3mm plywood spacer 8 Servo spacers
Plastic painted hub 1 Scale propeller hub
Plastic painted blade 4 Scale propeller blades
Decal sheet 2
ACCESSORIES
Plastic bomb 2
Plastic pylon 3 Bomb (2) center fuel tank (1)
Plastic centerline tank 1
4-40 x 41/2-inch thumb bolt 2 Optional centerline tank
4-40 x 1/2-inch socket head screw 4 Bombs to pylons
4-40 x 1-inch socket head screw 4 Pylon to wing
OPTIONAL AVAILABLE PARTS
Cockpit tub
Plywood tub with seat, dash and side panels 1
Plywood headrest with plastic cushion 1
ELECTRIC POWER
EP motor mount 1
EP plywood battery tray 8
4-40 x 1/2-inch socket head cap screw 2
#4 flat washer (black) 2
1
17
18
12
14
13
2
2
3
4
7
5
6
8
7
7
7
8
89
10
11
15
16
Replacement Parts
1. HAN448501 Fuselage with Fin and Hatch
2. HAN448503 Stabilizer Set with Elevator
3. HAN448504 Rudder
4. HAN448505 Fiberglass Cowl
5. HAN448506 Canopy
6. HAN448507 Aluminum Wing and Stabilizer
Tube
7. HAN448510 Plastic Scale Detail Set
8. HAN448511 Scale Bomb Set and Scale Fuel
Tank with Pylons
9. HAN448512 Landing Gear Doors
10. HAN448514 Optional EP Motor Plywood
Standoff and Battery Tray
11. HAN448515 Optional Cockpit Tub with
Cockpit kit
12. HAN448516 Fuel tank 22oz
13. HAN448517 51/8inch (130mm) Scale
8-spoke wheel
14. HAN448518 Fixed Wire Gear Struts
15. HAN448519 Tail Wheel Assembly
16. HAN2718 Scale Display Propeller
17. HAN448520 Right Wing Panel with Aileron
and Flap
18. HAN448521 Left Wing Panel with Aileron
and Flap
Items Not Shown
HAN448508 Pushrod Set
HAN448513 Decal Set
HAN448509 Hardware kit

5Hangar 9 P-47D-40 Thunderbolt 30cc ARF
Safety Precautions and Warnings
Read and follow all instructions and safety precautions
before use. Improper use can result in fire, serious injury
and damage to property.
Age Recommendation: Not for children under
14 years. This is not a toy.
COMPONENTS
Use only with compatible components. Should any
compatibility questions exist, please refer to the product
instructions, the component instructions or contact Horizon
Hobby, Inc.
FLIGHT
Fly only in open areas to ensure safety. It is recommended
flying be done at AMA (Academy of Model Aeronautics)
approved flying sites. Consult local ordinances before
choosing a flying location.
PROPELLER
Keep loose items that can get entangled in the propeller
away from the prop, including loose clothing or other objects
such as pencils and screwdrivers. Especially keep your
hands away from the propeller, as injury can occur.
BATTERIES
Notes on Lithium Polymer Batteries
Always follow the manufacturer’s instructions when using and
disposing of any batteries. Mishandling of Li-Po batteries can
result in fire causing serious injury and damage.
SMALL PARTS
This kit includes small parts and should not be left
unattended near children as choking and serious injury
could result.
Safe Operating Recommendations
• Inspectyourmodelbeforeeveryflighttoensureitis
airworthy.
• Beawareofanyotherradiofrequencyuserwhomay
present an interference problem.
• Alwaysbecourteousandrespectfulofotherusersin
your selected flight area.
• Chooseanareaclearofobstaclesandlargeenoughto
safely accommodate your flying activity.
• Makesurethisareaisclearoffriendsandspectators
prior to launching your aircraft.
• Beawareofotheractivitiesinthevicinityofyourflight
path that could cause potential conflict.
• Carefullyplanyourflightpathpriortolaunch.
• AbidebyanyandallestablishedAMANationalModel
Aircraft Safety Code.
Important Information
Regarding Warranty
Please read our Warranty and Liability Limitations in the
back of this manual before building this product. 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.
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 the steps completed.
Steps with a single box () are performed once, while steps
with two or more boxes () indicate 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.
UltraCote® Covering Colors
Silver HANU881
Cub Yellow HANU884
Olive Drab HANU904
Black HANU874
Deep Red HANU871
Recommended Power Setups
GAS
Evolution®40GX EVOE40GX
APC Propeller, 18 x 10 APC18010
Muffler, Inverted, Wraparound EVO30983400
Fuel Tubing, 3-foot Tygon DUB574
Chargeswitch JRPA004
Fuel Filler with T-Fitting and Overflow HAN116
11/2-inch P-47 B-Style Hub TRUTTH1500B
Adapter Kit, 10 x 1mm TRU0100
10-32 x 3/4-inch bolt kit TRUSCF10075
1800mAh 2S 7.4V ProLite Li-Po THP18002SPLRX
4-Pin Balance Extension THP4P10E
ELECTRIC
Power 160 Brushless Outrunner, 245Kv EFLM4160A
Phoenix HV-110 High Voltage ESC CSEPHX110HV
5S, 18.5V 5000mAh Li-Po Battery (2) EFLB50005S30
12-inch (305mm) Servo Extension SPMA3003
EC5™Battery Series Harness, 10AWG EFLAEC508
APC Propeller, 19 x 8 APC19080E
11/2-inch P-47 B-Style Hub TRUTTH1500B
10-32 x 3/4-inch bolt kit TRUSCF10075
Hook and loop tape (2)
Hook and loop strap (4)
Optional Retracts
Retract Mechanism, Main, with Air Kit HANP47
Retract Mechanism, Tail Wheel ROB160LWC
1/16-inch Threaded Ball Link (2) DUB190
Scale Straight Tread, 2-inch DUB110
12-inch (305mm) Servo Extension SPMA3003

6 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
Transmitter Requirements
This model requires a minimum 4-channel radio to operate
all the functions of your aircraft. We suggest the following
radio systems available through Horizon Hobby or your local
hobby distributor.
Spektrum™DX6i SPM6610
Spektrum DX7s SPM7800
Spektrum DX8 SPM8800
JR®DSM2™or DSMX®Systems
Radio Equipment Requirements
The following items are recommended when installing the
8-Channel AR8000 (SPMAR8000).
AR8000 8-Channel DSMX Receiver SPMAR8000
DSMX Remote Receiver SPM9645
JR Chargeswitch (ignition) JRPA004
2700mAh Receiver Battery, 6V JRPB5008
Standard Aircrtaft Servo SPMSA6050
Digital Aircraft Servo, A6010 (4) SPMSA6010
Digital Aircraft Servo, A6020 (3) SPMSA6020
12-inch (305mm) Servo Extension (2) SPMA3003
18-inch (457mm) Servo Extension (4) SPMA3004
Heavy-Duty Arms with Screws (2) JRPA215
JR Chargeswitch JRPA004
Servo Placement and Extensions:
Aileron: A6010 Standard Digital Servo (2)
12-inch (305mm) (2) inside wing from servo
18-inch (457mm) (2) inside fuselage from
receiver to extensions
Flaps: A6020 Digital Aircraft Servo (2)
Heavy-duty servo horn (2)
18-inch (457mm) (2) inside fuselage from
receiver to extensions
Rudder: A6020 Digital Aircraft Servo
Heavy-duty servo horn
Elevator: A6010 Digital Aircraft Servo (2)
Throttle: A6050 Standard aircraft servo
(not required for EP installations)
Optional Pilot Bust for Included
Cockpit Base Floor
1/5-Scale Pilot, Civilian with Headphones and
Sunglasses (Green) HAN9120
1/5-Scale Pilot, Civilian with Headphones and
Sunglasses HAN9127
* Optional pilot used for the full depth cockpit. We used an
Elite force 1/6 scale pilot
Optional Equipment
Telemetry for the DX8 SPM9548
6V, 2700mAh Ni-MH Battery JRPB5008
Y-harness (dual receiver battery) SPMA3008
Chargeswitch
(if using dual receiver batteries) JRPA004
Field Equipment Required
Ultra Fuel Pump (gas and glow) HAN155
Evolution Oil EVOX1001Q
Optional Field Equipment
PowerPro™12V Starter HAN161
Starter Source with 12V Ni-Cd HAN164
130mA Charger: Starter Source HAN166
Self-stick weights, 6 oz HAN3626
Charger EFL3025
Spray cleaner
Paper towels
Required Adhesives
30-minute Epoxy PAAPT39
Thin CA PAAPT08
Medium CA PAAPT02
Canopy Glue PAAPT56
Silicone adhesive DEVS250
Threadlock PAAPT42
Hardware/Accessory Sizes
Main wheel diameter 51/8in (130mm)
Tail wheel diameter 13/4in (44mm)
Fuel tank size 22 oz (650cc)
Wing tube size 11/4-inch x 293/8-inch
Wing bolt size 1/4-20 x 2-inch
Required Tools
Card stock
Covering iron
Dental floss
Dish washing detergent
Drill bit: 1/16-inch (1.5mm), 5/64-inch (2mm), 1/8-
inch (3mm), 7/32-inch (5.5mm), 1/4-inch (6mm)
Epoxy brushes
Felt-tipped pen
Flat file
Hex wrench: 1.5mm, 3/32-inch, 7/64-inch
Hobby knife with #11 blade
Hobby scissors
Hook and loop tape
Isopropyl alcohol
Light machine oil
Low-tack tape
Medium grit sandpaper
Mixing cups
Mixing sticks
Needle nose pliers
Paper towels
Pencil
Petroleum jelly
Phillips screwdriver: #1, #2
Pin vise
Propeller reamer
Razor saw
Rotary tool
Ruler
Sanding drum
Scissors
Side cutters
Spray bottle
Square
Straight edge
String
Tie wraps
Toothpicks
T-pins
Two-sided tape

7Hangar 9 P-47D-40 Thunderbolt 30cc ARF
Before Starting Assembly
Before beginning the assembly of your model, 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 the place
of purchase.
If you find any wrinkles in the covering, use a heat gun
(HAN100) and covering glove (HAN150) or covering iron
(HAN101) with a sealing iron sock (HAN141) to remove
them. Use caution while working around areas where the
colors overlap to prevent separating the colors.
Binding the Radio System
Before starting the assembly of your model, we recommend
preparing your radio system for installation. This includes
charging the transmitter and receiver batteries, as well as
centering the trims and sticks on your transmitter. If using
a computer radio, make sure to reset a model memory
and name it for this particular model. We also recommend
binding the transmitter and receiver at this time, following
the instructions provided with your radio system.
 We highly recommend re-binding the radio
system once all the control throws are set. This will
keep the servos from moving to their endpoints
until the transmitter and receiver connect.
Aileron and Flap Installation
Required Parts
Wing panel (left and right)
Aileron (left and right) Flap (left and right)
CA hinge (6) Pinned hinge (6)
 Make sure to follow the procedure outlined
in this manual for hinging the control surfaces.
Failure to do so could lead to the control surfaces
becoming loose, which may cause a crash.
1. Locate the items for this section of the manual.
 2. Use a pin vise and 1/16-inch (1.5mm) drill bit to
drill a hole in the center of the hinges slots. Prepare both the
aileron and wing at this time.
 3. Place two T-pins in each of the three CA hinges as
shown. This will center the hinge evenly between the wing
and aileron when the hinges are installed.
 4. Insert the hinge in the aileron hinge slots. Center
the opening in the center of the hinge with the hole drilled in
step 2. The T-pins will rest on the leading edge of the aileron
when the hinge is installed. Install all three hinges at this
time.

8 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 5. Slide the aileron into position, guiding the hinges
into the slots in the wing. With the aileron pressed tight
against the wing, remove the T-pins. Use a few small pieces
of low-tack tape to hold the aileron in position. Do not glue
the hinges until instructed to do so.
 6. Prepare the three pinned hinges by applying light
machine oil to the hinge point. This will help prevent the
adhesive from entering the hinge and causing it to not move.
 7. Insert the three hinges into the holes in the flap.
Test fit the flap to the wing. Position the hinges so the flap is
aligned with the wing and can move freely without binding.
 8. Once satisfied with the fit, note the position of the
hinges. Remove the flap and hinges. Mix a small amount of
30-minute epoxy and glue each hinge into position in the flap
and wing. Use a toothpick to apply epoxy in both the holes
for the hinges and to the hinges themselves.
 9. Place the flap and hinges back into position and use
low-tack tape and a small piece of plywood clamped to the
wing to keep the flap in position until the epoxy fully cures.
Use a paper towel and isopropyl alcohol to remove any
excess epoxy.
 10. Once the epoxy has cured, remove the tape and
clamps. If any of the flap hinges (only the flap hinges)
appear to be loose, apply thin CA to the hinge where it enters
the flap and wing to complete the flap hinging process.

9Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 11. Position the aileron so the gap between the wing
tip and aileron matches the gap between the aileron and flap.
With the aileron pressed tightly against the wing, saturate
the top and bottom of each hinge with thin CA so the CA
wicks into the hinge and into the surrounding wood.
 Do not use CA accelerator when gluing the hinges.
Always allow the CA to soak into the hinge for the best
bond between the hinge and surrounding wood.
 12. Once the CA has fully cured, check that the hinges
are secure by gently pulling on the control surface. If not,
apply thin CA to any loose hinges and recheck. Move the
control surface through its range of motion several times to
break in the hinges. This will reduce the initial load on the
servo during your first flights.
13. Repeat steps 2 through 12 to install the remaining
aileron and flap to the wing panel.
Aileron and Flap Servo
Linkage Installation
Required Parts
Metal clevis (8) 4-40 nut (8)
Transmitter Receiver
Nylon control horn (2) Silicone clevis retainer (8)
Wing panel (left and right) Flap servo with hardware (2)
Receiver battery Switch harness
12-inch (305mm) servo extension (2)
Heavy-duty servo arm (JRPA215) (2)
Aileron servo with hardware (2)
M2.5 x 10 sheet metal screw (30)
Flap pushrod: 4-40 x 55mm, threaded both ends (2)
Aileron pushrod: 4-40 x 76mm threaded both ends (2)
1. Locate the items for this section of the manual.
 2. Prepare the servo by installing the grommets and
brass eyelets. Attach a 12-inch (305mm) servo extension,
securing it to the servo lead using string or dental floss.
 Check that the servo horn will be centered
in the slot when the servo is installed, as some
servos have a short upper case. If the servo arm
does not center, then you will need to use medium
CA to glue the included servo spacer to the mount
to move the servo so the arm is centered.
 3. Use a pin vise and a 1/16-inch (1.5mm) drill bit to
enlarge the holes in the aileron servo cover for mounting
the servo. Thread a servo mounting screw in each hole
using a #1 Phillips screwdriver. Remove the screw, then
apply 1–2 drops of thin CA in each hole to harden the
surrounding wood.

10 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 4. Mount the aileron servo to the servo cover using the
screws provided with the servo and a #1 Phillips screwdriver.
 5. Use the radio system to center the aileron servo.
Install a servo horn that will allow you to attach the clevis
to a hole in the horn that is 21/32 inch (17mm) from the
center of the horn. When installing the horn, rotate it one
spline towards the leading edge of the wing. This will help
improve the aileron pushrod clearance and will also aid in
achieving the aileron differential throw listed in the control
throw section of the manual. Use side cutters to remove any
arms from the horn that could interfere with the operation of
the servo.
 6. Prepare the six holes for the cover mounting
screws by threading an M2.5 x 12 sheet metal screw in each
hole using a #1 Phillips screwdriver. Remove the screw,
then place 1–2 drops of thin CA in each hole to harden the
surrounding wood.
 7. Tie the string to the servo extension and use it to
pull the extension through the wing. Secure the servo cover
in the wing using six M2.5 x 12 sheet metal screws and a #1
Phillips screwdriver.
 8. When installing the aileron control horn, it must
be positioned in-line with the servo horn so the linkage will
be square to the aileron hinge line. Use a square and felt-
tipped pen to mark the aileron for the proper position for the
control horn.
90 degrees

11Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 9. Use a hobby knife with a #11 blade to remove
the backplate from the control horn. Position the horn on
the aileron so it is centered on the mark made in step 8.
The front of the horn will be back 1/16 inch (1mm) from
the bevel of the aileron. Use a felt-tipped pen to mark the
locations for the three control horn mounting screws.
 10. Use a drill and a 1/16-inch (1.5mm) drill bit to drill
the three holes for the control horn mounting screws. The
holes only need to be 3/8 inch (10mm) deep for the screws.
Do not drill through the top of the aileron. Use a #1 Phillips
screwdriver to thread an M2.5 x 12 sheet metal screw in
each hole. Remove the screw and place 1–2 drops of thin
CA in each hole to harden the surrounding wood. Attach the
control horn using three M2.5 x 12 sheet metal screws and a
#1 Phillips screwdriver.
 11. Assemble the aileron linkage as shown using a
4-40 x 76mm pushrod, two metal clevises, two 4-40 nuts
and two silicone clevis retainers. Adjust the clevises so the
pins of the clevises are 4 inches (102mm) apart.
 12. Attach the aileron linkage to the servo horn and
the center hole of the control horn. With the radio system
on and the aileron servo plugged into the receiver, adjust
the clevis so the aileron is aligned with the trailing edge at
the wing tip. With the threaded rod position evenly in the
clevises, use needle nose pliers to tighten the nuts against
the clevises and use threadlock on the nuts and clevises
to prevent them from vibrating loose. Slide the silicone
retainers over the clevises to prevent them from opening
during flight.
 13. Assemble the flap linkage as shown using a 4-40
x 55mm pushrod, two metal clevises, two 4-40 nuts and
two silicone clevis retainers. Adjust the clevises so the pins
of the clevises are 31/4inches (83mm) apart. Leave the nuts
and clevises loose so the linkage can be adjusted.
 14. Insert the linkage into the opening in the
trailing edge near the flap control horn. Attach one of
the clevises to the flap control horn. Slide the silicone
clevis retainer over the forks of the clevis to keep it from
opening accidentally.

12 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 15. Use a pin vise and a 1/16-inch (1.5mm) drill bit
to enlarge the holes in the flap servo cover for mounting
the servo. Thread a servo mounting screw in each hole
using a #1 Phillips screwdriver. Remove the screw, then
apply 1–2 drops of thin CA in each hole to harden the
surrounding wood.
 16. With the radio flap switch and flap servo in the
UP position, attach the heavy-duty servo arm that will allow
you to attach the clevis to a hole in the horn that is 7/8
inch (22mm) from the center of the horn. When installing
the horn, rotate it one spline forward from center toward
the leading edge. Use side cutters to remove any arms
from the horn that could interfere with the operation of
the servo. Mount the servo using the hardware provided
with the servo so the output of the servo faces toward the
leading edge of the wing.
 17. Attach the clevis to the servo horn. Position the
servo in the opening. If the servo does not fit because the
linkage length is incorrect, adjust the linkage. Do not force
the servo into position. With the servo in the wing, check
that the flap is in the UP position. Adjust the linkage or
travel rate as necessary for UP flap. Once the linkage is
set, apply threadlock to the nuts and clevises. Tighten the
nuts against the clevises using pliers to keep the clevises
from vibrating loose. Follow step six to prepare the holes
in the wing for the flap cover screws. The flap cover is then
secured to the wing using six M2.5 x 10 sheet metal screws
and a #1 Phillips screwdriver.
18. Repeat steps 2 through 17 to install the remaining
flap servo and linkage.
Fixed Main Gear Installation
Required Parts
Wing panel (left and right)
6mm wire strut (2) Metal mount (2)
M4 x 4 setscrew (2) 6mm plywood bracket (4)
51/8-inch (130mm) main wheel (2)
6mm wheel collar with setscrew (4)
6-32 x 1-inch socket head cap screw (8)
Landing gear cover, outer (left and right)
1. Locate the items for this section of the manual.
 2. Slide two of the 6mm plywood brackets on a 6mm
wire strut. Use an M4 x 4 setscrew to secure the wire strut in
the metal mount. Use threadlock on the setscrew to prevent
it from vibrating loose. The setscrew will tighten on the flat
area on the strut using the included hex wrench. You will be
building a left and right unit.

13Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 Paint the 6mm plywood brackets using
black or silver paint to make them blend
in the with struts of gear doors.
 3. Secure the metal mount in the wing using four 6-32
x 1-inch socket head screws and a 7/64-inch hex wrench.
Make sure to use threadlock on the screws to prevent them
from vibrating loose. The axle will face toward the root of the
wing when installed as shown in step 5.
 4. Use a pencil to draw a centerline on the back of the
gear door. Mark the door 1 inch (25mm) from the bottom for
the location of the lower plywood bracket.
 5. The landing gear door is glued to the plywood
brackets using medium CA. Glue the upper bracket flush to
the edge of the door and the lower bracket at the mark made
in the previous step. Use the centerline to position the door
with the landing gear wire.
 6. Position the door so the bottom edge is aligned with
the axle. Also check that the door is perpendicular to the
axle. Use silicone adhesive to secure the plywood brackets
to the strut so the brackets can’t rotate on the strut. Use a
rotary tool and cut-off wheel to trim the axle to a length of
11/8inch (29mm).
 7. Use a flat file to make two flat areas on the bottom
of the axle that are 1/4-inch (6mm) wide. The first is
centered 3/16 inch (5mm) from the end of the axle, the
second is 1 inch (25mm) from the end of the axle.

14 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 8. Remove the hub cap from the wheel.
 Place a drop of light machine oil on
the axle before installing the wheel so
they will rotate freely on the axles.
 9. Slide the inner wheel collar on the axle. Use a
1.5mm hex wrench to tighten the setscrew. Use threadlock
on the setscrew to prevent it from vibrating loose. Slide the
wheel on the axle.
 10. Secure the wheel using another wheel collar that
will be flush to the outside edge of the axle. Tighten the
setscrews using a 1.5mm hex wrench. Make sure to use
threadlock on the setscrews to prevent them from vibrating
loose. Install the hub cap back on the wheel once the
setscrews are tightened.
11. Repeat steps 2 through 10 to install the remaining
landing gear and wheel.
Optional Retractable
Main Gear Installation
Required Parts
Wing panel (left and right)
Retract mechanism (left and right)
51/8-inch (130mm) main wheel (2)
6-32 x 1-inch socket head cap screw (8)
Air line, red and purple
Quick disconnect (2)
4-40 x 1/4-inch socket head screw (4)
#4 washer (4)
Outer landing gear cover stiffener (2)
Landing gear cover, outer (left and right)
Landing gear cover, inner (left and right)
1. Locate the items for this section of the manual.

15Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 2. Use a hobby knife and #11 blade to remove the
covering from the retract opening. Use a trim seal tool to
iron the covering around the edge of the opening.
 3. Cut a piece of red and purple air line to a length
of 15 inches (381mm). Place a quick disconnect on each
line. Make sure to use one connector with the O-ring and
one without to avoid connecting the lines incorrectly.
Guide the air lines through the openings in the wing from
the root to the retract mount. Fittings have been installed
to route the air line so it doesn’t interfere when the
retracts are in the UP position.
 4. Attach the air lines to the retract. Note the
orientation of the lines and how they are connected.
 Before securing the main gear, we recommend
running a 6/32 x 1-inch socket head screw with a
7/64-inch hex wrench through each of the blind
nuts to remove any paint that may have entered the
blind nut during the assembly of your model.
 5. Secure the retract mechanism in the wing using four
6-32 x 1-inch socket head cap screws and a 7/64-inch hex
wrench. The scissor link will face toward the leading edge
of the wing. Make sure to use threadlock on the screws to
prevent them from vibrating loose.
 6. Enlarge the hole in the wheel using a drill and
1/4-inch (6mm) drill bit. Secure the wheel to the retract
mechanism using the axle and setscrew provided with the
retract. Use a rotary tool and cutoff wheel to trim the axle so
it is flush with the retract strut. Use a flat file to make a flat
area for the setscrew to tighten to so the axle won’t come
loose. Also use threadlock on the setscrew before tightening
it with a 3/32-inch hex wrench.

16 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 7. Check the operation of the retract. You will find the
wing rib requires slight trimming toward the leading edge
to clear the wheel and allow the retract to lock in the UP
position. This is necessary as the assembly of the wing can
not be accomplished if the rib is trimmed to fit the wheel
during production.
 8. Move the retract to the UP position. Make sure
the gear is fully retracted and locked into position. Failure
to lock the wheel could cause a misalignment of the door
in the following steps. Use a straight edge and align
it with the holes in the strut for mounting the landing
gear cover. Use a felt-tipped pen to mark the wing at the
opening and mounting area as alignment points for the
cover mounting screws.
 9. Use the same process to make marks at the front and
rear of the opening to locate the mounting screw locations.
 10. Use low-tack tape to hold the landing gear cover in
position. Use a felt-tipped pen to mark the locations for the
mounting screws using the lines made on the wing.
 11. Use a 1/8-inch (3mm) drill bit and a pin vise to
drill the two holes for the mounting screws. Temporarily
secure the cover to the retract using two 4-40 x 1/4-inch
socket head screws and two #4 washers. The holes can be
enlarged slightly to position the cover so it aligns correctly in
the opening.
 12. With the retract in the DOWN position, place the
stiffener so it almost touches the landing gear strut. This is
necessary so it will clear the surrounding structure. Use a
felt-tipped pen to mark the location of the stiffener on the
gear door.

17Hangar 9 P-47D-40 Thunderbolt 30cc ARF
 13. Remove the gear door. Place two pieces of
low-tack tape where the stiffener will be positioned. Use
sandpaper to roughen the area to provide a surface to glue
the stiffener to the gear door. The tape will prevent removing
the paint from the surrounding area. Once prepared, use
medium CA to glue the stiffener to the gear door.
 The inner gear door can be made operational.
Please refer to the tutorial on-line for details on the
operational installation of the inner gear door.
 14. Reinstall the gear door. Make sure to use
threadlock on the screws to prevent them from vibrating
loose. Check the operation of the retracts to make sure the
position of the doors is correct. Enlarge the holes that secure
the door to the strut if necessary to fine-tune their alignment
to the wing. Trim the inner gear door covers to clear the
wheel when the gear is retracted. Once trimmed, use canopy
glue to glue the inner covers into position. This will make the
inner gear door covers easily removable if you want to install
removable gear doors in the future.
15. Repeat steps 2 though 14 to install the remaining
retract assembly.
Rudder Installation
Required Parts
Fuselage Rudder
CA hinge (3)
1. Locate the items for this section of the manual.
2. Use a pin vise and 1/16-inch (1.5mm) drill bit to drill a
hole in the center of the three hinges slots. Prepare both the
rudder and fin at this time.
3. Place two T-pins in each of the three CA hinges as
shown. This will center the hinge evenly between the rudder
and fin when the hinges are installed.
4. Insert the hinge in the rudder hinge slots. Center the
opening in the hinge with the hole drilled in step 2. The
T-pins will rest on the leading edge of the rudder when the
hinge is installed. Install all three hinges at this time.

18 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
5. Slide the rudder into position, guiding the hinges into
the slots in the fin. With the rudder pressed tight against the
fin, remove the T-pins.
6. Position the rudder so it is aligned with the bottom
of the fuselage. Saturate both sides of the hinges with
thin CA so the CA wicks into the hinge and into the
surrounding wood.
 Do not use CA accelerator when gluing the hinges.
Always allow the CA to soak into the hinge for the best
bond between the hinge and surrounding wood.
7. Once the CA has fully cured, check that the hinges are
secure by gently pulling on the control surface. If not, apply
thin CA to any hinges that are not glued and recheck. Move
the control surface through its range of motion several times
to break in the hinges. This will reduce the initial load on the
servo during your first flights.
Fixed Tail Wheel Installation
Required Parts
Fuselage Tail wheel wire, 3mm
Tail wheel, 1.75 inch Metal steering arm
#4 flat washer (6) Braided cable
4-40 nut (2) 4-40 metal clevis (2)
4-40 threaded eyelet (2) Silicone clevis retainer (2)
Tail wheel plastic hatch Copper tubing crimp (4)
Nylon tail wheel support mount
M2.5 x 12 sheet metal screw (5)
M3 wheel collar with setscrew (4)
Nylon tail wheel support bracket
4-40 x 1/2-inch socket head screw (6)
1. Locate the items for this section of the manual.

19Hangar 9 P-47D-40 Thunderbolt 30cc ARF
2. Position the tail wheel hatch over the opening for the
tail wheel. We used low-tack tape to indicate the front edge
of the opening. Use a felt-tipped pen to mark the cover so it
can be trimmed to the correct length.
3. Use hobby scissors, a rotary tool with a sanding drum
and medium grit sandpaper to trim the cover to the correct
length. Work slowly, fitting the cover to make sure it is not
trimmed too much.
4. Slide the nylon tail wheel support bracket on the tail
wheel wire. The rounded corners will face toward the tail
wheel. Slide the steering arm and wheel collar on the wire,
and secure then to the flat areas of the wire using a setscrew
and 1.5mm hex wrench. Use threadlock on the setscrews to
prevent them from vibrating loose. Note the orientation of
the steering arm in relationship to the wire.
5. Slide the nylon tail wheel support mount on the
wire. The mount is then secured using a wheel collar and
setscrew. Make sure the wire can move freely in the mount
and that the collars don’t allow the wire to move excessively
in the mount.
6. Remove the canopy hatch from the fuselage by
pressing the release using a #1 Phillips screwdriver. The
canopy will lift at the rear and has tabs at the front. Set the
hatch aside until later.
7. Insert the cable into the two tubes as shown. Pull the
cable so equal parts extend outside the fuselage. The tubes
are numbered, so insert the cable into tubes 5 and 6.

20 Hangar 9 P-47D-40 Thunderbolt 30cc ARF
8. Prepare the cable ends in the tail wheel opening by
passing the cable through a copper crimp, then through the
hole in the 4-40 threaded eyelet. The cable then goes back
through the crimp. Use crimping pliers to compress the crimp,
securing the wire. Prepare one end of both wires at this time.
9. Thread a 4-40 nut on the eyelet. Slide a silicone clevis
retainer on the 4-40 clevis, then thread the clevis on the
eyelet so the threads are just visible between the forks of
the clevis. Tighten the nut against the clevis using pliers to
prevent the clevis from vibrating loose. Use threadlock on
the clevis and nut as well.
10. Attach the clevises to the middle holes on the
steering arm, then slide the clevis retainers over the forks of
the clevis to make sure they don’t open accidentally. Check
that the cables will not cross in the rear of the fuselage when
the tail wheel is installed.
 After initial test flights, you can move the
clevis in or out to obtain the desired amount
of tail wheel throw. Moving the clevis in will
increase the amount of throw, while moving the
clevis out will decrease the amount of throw.
11. Mount the tail wheel assembly in the fuselage
using four 4-40 x 1/2-inch socket head screws and four #4
washers to attach the mount to the fuselage. The mount
only fits in one direction, so rotate it until all four holes are
aligned. The bracket is attached using two 4-40 socket head
screws and two #4 washers. Use threadlock and a 3/32-inch
hex wrench to tighten the screws.
12. Measure from the front edge and the sides of the
opening in the fuselage to locate the tail wire. Transfer the
measurement to the cover, then use a pin vise and 1/8-
inch (3mm) drill bit to drill a hole in the cover. Fit the cover
and enlarge the hole using a hobby knife and #11 blade as
necessary so the tail wheel wire is centered in the hole when
the cover is in position.
13. The cover is secured to the fuselage using five M2.5
x 12 sheet metal screws. Use a pin vise and 1/16-inch
(1.5mm) drill bit to drill the holes. Use a felt-tipped pen
to mark the position of the former on the fuselage so the
screws can be located when they thread into the former. Use
a #1 Phillips screwdriver to install the screws.