Hangar 9 Piper Cherokee User manual

INSTRUCTION MANUAL
ALMOST READY-TO-FLY
PRE-BUILT
90
%
• Extensive Hardware Included to Save Money
• Pre-Covered Realistic Trim Scheme
• Semi-Symmetrical Airfoil
Specifications
Wingspan: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62"
Length:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1/2"
Wing Area:. . . . . . . . . . . . . . . . . . . . . . . . . . . 720 sq. in.
Weight (Approx.):. . . . . . . . . . . . . . . . . 6–6.25 lbs.
Recommended Engines:. . . .40–.46 2-cycle
.45–.56 4-cycle
PIPER
WE GET PEOPLE FLYING
TM
TM

2
Table of Contents
Introduction 3
Warning 3
Additional Equipment Required 3
Tools and Supplies Required 4
Contents of Kit 5
Field Equipment Required 6
Optional Field Equipment 7
Section 1: Assembling the Wings 8
Section 2: Joining the Wing Halves 10
Section 3: Installing the Aileron Servo Tray 14
Section 4: Mounting the Wing 18
Section 5: Assembling the Fuselage 20
Section 6: Installing the Tail 23
Section 7: Hinging the Vertical & Horizontal Stabilizers 27
Section 8: Installing the Control Horns 28
Section 9: Assembling and Installing the Fuel Tank 30
Section 10: Installing the Landing Gear 33
Section 11; Installing the Nose Gear 35
Section 12: Assembling and Mounting the Wheel Pants 36
Section 13: Installing the Engine 38
Section 14: Installing the Cowling 39
Section 15: Installing the Radio 41
Section 16: Installing the Linkages 44
Section 17: Plumbing the Engine 49
Section 18: Control Throw Recommendations 50
Section 19: Balancing the Cherokee 50
Pre-Flight Check 51
Pre-Flight at the Flying Field 52
AMA Safety Code 53

Introduction
Congratulations on your purchase of the Hangar 9 Piper Cherokee. This is the ideal second airplane for modelers who are capable of
flying a trainer-type aircraft. In a few short evenings, this 90% pre-built beauty will be ready for its debut at the flying field.
This manual has been written to ensure that you achieve the best performance and maximum enjoyment from your Piper Cherokee. It
is important to carefully read and follow the instructions in this manual prior to flying the Piper Cherokee.
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
AMA (Academy of Model Aeronautics) approved flying sites, following all instructions included with your radio and engine.
Additional Equipment Required
Radio Equipment:
4 Channels (minimum)
4 Standard Servos
Standard 450-650 mAh Receiver Battery Pack
Recommended JR Systems:
JR F400 FM
JR XF642
JR XP783
JR XP8103
Engine Recommendations:
.40 - .46 2-Cycle Engines
.45 - .56 4-Cycle Engines
Recommended 2-Cycle Engines: Recommended 4-Cycle Engines:
MDS .40FS Saito .50
MDS .46FS Saito .56GK
MDS .48FS
Webra Speed .40 Sport
3

4
Tools and Supplies Required
Adhesives
Thin CA (cyanoacrylate) glue
Thick CA (cyanoacrylate) glue
6-minute epoxy
12-minute epoxy
30-minute epoxy
Blue Locktite 242
Canopy glue
Tools
Drill
Drill bits: 1/16′′, 5/32′′
Small Phillips screwdriver
Medium Phillips screwdriver
Z-bend pliers
Pliers
Small round file
Razor saw
Moto-Tool with sanding drum
Hobby knife with #11 blade
Mixing stick
Epoxy brush 90-degree triangle
File
Sanding stick (medium or fine)
Medium sandpaper
Masking tape
Straight edge
Measuring device (e.g., ruler, tape measure)
Scissors
Paper towels
Wax paper
Rubbing alcohol
Felt tipped pen
Fuel tubing
Clips (e.g., clothespins, binder clips)
Radio packing foam
Antenna tube

5
Contents of Kit
Covered Parts
A. Fuselage D. Vertical stabilizer with rudder
B. Left wing half with aileron E. Horizontal stabilizer with elevator
C. Right wing half with aileron
Other
1. Pushrod & accessories 9. Foam wheels (3)
2. 1/8′′ plywood die-cut parts 10. Fuel tank and hardware
3. Main landing gear 11. Seats (not shown)
4. Nose landing gear 12. Cowling (not shown)
5. Spinner 13. Windshield
6. Hardware bag 14. Clear plastic for windows (not shown)
7. Plastic parts tree 15. Trim sheet (not shown)
8. Wheel pants (3) (not shown) 16. Motor mount
13
3
10
6
5
7
16
1
4
2
9
A
C
B
E
D

6
Field Equipment Required
Airplane Fuel
Propeller
Glow Driver
Glow Plug Wrench
Glow Plug Manual Fuel Pump

7
Optional Field Equipment
Starter
12V Sealed Battery
4-Way Wrench Field Box Cleaner & Towels
Extra Glow Plugs Misc. Tools After-Run Fuel
Power Panel #64 Rubber Bands

8
Step 1. Carefully remove the aileron from the right wing panel
by pulling straight out with even pressure. Note the location of
the hinges and the aileron torque rod; this will be of assistance
when replacing the aileron onto the wing.
Step 2. Remove all four hinges from the aileron. Flex the hinges
so they move freely.
Step 3. Mix a small amount of 30-minute epoxy. Using either a
mixing stick or a small piece of scrap wood, apply the epoxy
sparingly inside each hinge slot on the aileron. Additionally,
apply a small amount of epoxy to the top and bottom half of each
hinge. Insert the hinges into the aileron until the hinge line is
even with the leading edge of the aileron.
Note: Do NOT apply any epoxy into the aileron torque rod
hole at this time.
Step 4. Lightly coat both ends of the aileron with epoxy; this
will prevent the aileron from becoming fuel soaked.
Step 5. Wipe off any excess epoxy using a paper towel and
rubbing alcohol.
Section 1: Assembling the Wings
• Right wing panel with aileron and hinges
• Left wing panel with aileron and hinges • 30-minute epoxy • Paper towels
• Rubbing alcohol
• Mixing stick/epoxy brush
• Ruler
• Wax paper
Parts Needed Tools and Adhesives Needed

9
Step 6. Mix a small amount of 30-minute epoxy to install the
aileron onto the wing half. Apply epoxy to the top and bottom of
the remaining half of each hinge, as well as the aileron torque
rod hole. Using either a mixing stick or a piece of scrap wood,
apply epoxy inside each hinge slot on the wing.
Step 7. Replace the aileron on the right wing half. Make sure
the hinges are properly aligned and that the aileron torque rod
presses into its respective hole in the aileron. The use of a piece
of wax paper between the torque rod and wing will prevent epoxy
from adhering to the wing. The gap between the aileron and the
wing should remain a constant 1/16′′, or as tight as possible
without restricting the movement of the aileron.
Step 8. Carefully wipe off any excess epoxy using a paper towel
and rubbing alcohol.
Step 9. Repeat the procedures above for the left wing half.
Step 10. Allow the epoxy to cure before proceeding to the next
section.
CONTINUED
Section 1: Assembling the Wings

10
Step 1. Carefully remove the three individual wing joiners from
the parts bag. If necessary, sand gently to remove any rough
edges.
Step 2. Mix a small amount, approximately 1/4 oz., of 6-minute
epoxy. Using either a mixing stick or epoxy brush, apply the
epoxy to both sides of one of the wing joiners. Place the
epoxied wing joiner on top of one of the two remaining wing
joiners. Stack the remaining wing joiner on top of the epoxied
wing joiner. Align the upper and lower edges of all three wing
joiners, as well as the area which has the slight “V” shape.
Step 3. Clamp the three joiners together using clothespins or
clips. Make sure the joiners remain aligned and the clamps are
firmly attached.
Step 4. Wipe away the excess epoxy using a paper towel and
rubbing alcohol. Be careful not to disturb the alignment of the
wing joiners.
Note: Any excess epoxy should be removed before it cures.
Section 2: Joining the Wing Halves
• Right wing panel from Section One
• Left wing panel from Section One
• Three plywood wing joiners
• 6-minute epoxy
• 30-minute epoxy
• Clips (e.g., clothespins, binder clips)
• Rubbing alcohol
• Paper towels
• Masking tape
• Wax paper
• Ruler
• Pencil
• Medium sandpaper
• Mixing stick/epoxy brush
• Felt tipped pen
Parts Needed Tools and Adhesives Needed

11
Step 5. Allow the epoxy to cure completely prior to removing
the clamps.
Step 6. Using a pencil and ruler, mark the “V” section of the
brace. This mark will serve as the center line when joining the
wing halves.
Step 7. Trial fit the dihedral brace, or wing joiner, into one of
the wing panels. It should insert smoothly up to the center line
marked in Step 6. Now slide the other wing half onto the
dihedral brace until the wing panels meet. If the fit is overly tight,
it may be necessary to lightly sand the dihedral brace.
Step 8. Check for the correct dihedral angle. Place the wing on
a large, flat surface with one wing panel resting on the surface.
The opposite wing tip should be exactly 1-3/4′′ from the surface
(see illustration below). If necessary, sand the dihedral brace
until this is achieved.
Step 9. Place the wing halves on the flat surface so the white
side (bottoms) are facing downward. Using a felt tipped pen,
place a mark at the leading edge and trailing edge of the servo
bay on each wing half. These marks will be utilized as a guide
when cutting the holes for the aileron servo and the aileron servo
tray.
Step 10. Mix up approximately three ounces of 30-minute
epoxy.
Note: When joining the wing halves, it is extremely
important to use plenty of epoxy.
Step 11. Using a mixing stick or scrap piece of wood, apply a
generous amount of epoxy into the wing joiner cavity of one
wing half. Be sure that the epoxy is applied to all sides of the
cavity.
CONTINUED
Section 2: Joining the Wing Halves
13/4"

12
Step 12. Coat one half of the dihedral brace with epoxy up to
the center line drawn in Step 6. Install the epoxy-coated side of
the dihedral brace into the wing joiner cavity up to the center
line, making sure that the “V” of the dihedral brace is positioned
correctly.
Step 13. Apply a generous amount of epoxy into the wing
cavity of the other wing half.
Step 14. Smear epoxy on all sides of the exposed area of the
dihedral brace and uniformly coat both wing roots with epoxy.
CONTINUED
Section 2: Joining the Wing Halves

13
Step 15. Carefully slide the two wing halves together, ensuring
they are accurately aligned. Firmly press the two halves together,
allowing the excess epoxy to run out. Using rubbing alcohol and
a paper towel, clean off the excess epoxy. There should not be
any gap between the wing halves.
Step 16. Apply masking tape to the wing joint to hold the wing
together securely while the epoxy cures. Place the wing on a
large, flat surface. With one wing panel lying flat on the surface,
the opposite wing tip should be propped up exactly 1-3/4′′ from
the surface. Allow the wing joint to dry overnight.
Note: It is a good idea to place a sheet of waxed paper under
the center joint of the wing so that any excess epoxy
doesn’t adhere to the surface of the work area.
CONTINUED
Section 2: Joining the Wing Halves

14
Step 1. After the wing joint has completely cured, remove the
masking tape.
Step 2. Remove the aileron servo tray and the two aileron tray
supports from the parts bag.
Note: One of the aileron support trays is slightly shorter
than the other. The shorter support will be situated
toward the trailing edge of the wing.
Step 3. Place the aileron servo tray between the marks that were
made previously in Section 2, Step 9. Center the tray across the
seam between the wing halves.
Step 4. Tape the tray in place with two pieces of masking tape,
ensuring that the alignment is not disturbed.
Step 5. Using a felt tipped pen, trace around the outside upper
and lower parallel edges of the servo tray. These marks will
serve as the guides for cutting the servo tray support slots later
in this section. Additionally, place a mark along each of the
outside vertical edges of the tray. These marks will be the outer
edges of the servo tray support slots.
Section 3: Installing the Aileron Servo Tray
• Plywood aileron tray
• Plywood aileron tray supports
• Aileron servo
• Wing center tape
• Masking tape
• Hobby knife
• Felt tipped pen
• 6-minute epoxy
• Thick CA glue
• Epoxy brush
• Rubbing alcohol
• Paper towels
• Scissors
Parts Needed Tools and Adhesives Needed

15
Step 6. Using a felt tipped pen, trace around the inside edge of
the aileron servo tray and then remove it from the wing.
Step 7. With a sharp hobby knife, carefully cut a 1/8′′ wide slot
which is 1-5/8′′ in length through both the covering and the
balsa wood along the lines which were drawn in Step 5 of this
section. Remove the excess balsa from the slots.
Step 8. Trial fit the aileron tray supports into the slots. It may be
necessary to enlarge the slot slightly to accommodate the
support.
Step 9. Using the sharp hobby knife, carefully cut through the
balsa wood and the covering along the lines that were drawn in
Step 6 of this section. Remove the excess balsa from the hole.
Step 10. Trial fit the aileron servo into the servo tray. Also, trial
fit the servo into the hole cut in the wing in Step 9 to see if it will
fit. It may be necessary to enlarge either the servo tray or the
servo hole slightly, depending upon the dimensions of the
aileron servo.
CONTINUED
Section 3: Installing the Aileron Servo Tray

16
Step 11. Mix a small amount of 6-minute epoxy and apply it to
one of the aileron servo supports between the two tabs. Position
the aileron servo tray in place as shown and lightly spread epoxy
along the joint between the aileron servo tray and the aileron
servo support.
Note: If desired, thick CA may be used in this procedure
instead of epoxy.
Step 12. Repeat this procedure for the opposite aileron servo
support. Make sure the aileron servo support and the servo tray
remain perpendicular to one another. Allow the epoxy or CA to
dry completely before proceeding to the next step.
Step 13. Mix a small amount of 6-minute epoxy to glue the
servo tray into the wing. Using an epoxy brush, apply the epoxy
to the aileron servo supports. Insert the assembled unit into its
receptacle in the wings. Remove any excess epoxy with a paper
towel and rubbing alcohol and allow the epoxy to cure.
Important Note: The shorter aileron support must be
located closest to the trailing edge of the
wing.
CONTINUED
Section 3: Installing the Aileron Servo Tray

17
Step 14. Locate the wing center tape and remove the adhesive
backing. Starting at the front of the aileron servo tray, wrap the
tape completely around the wing joint seam to the rear of the
servo tray. Gently pulling on the tape while pressing it down
onto the wing will provide a smooth seam. Cut any excess tape
with a pair of scissors.
Note: You will install the aileron servo in Section 15.
CONTINUED
Section 3: Installing the Aileron Servo Tray

18
Step 1. Locate the four wing dowel holes. First, locate the two
which are located inside the fuselage bottom where the leading
edge of the wing rests have been pre- drilled.
Step 2. Next, locate the two holes in the leading edge of the
wing. You will need to trim the covering over the holes. Mix a
small amount of 12-minute epoxy and apply it to the two
wooden dowels. Insert the dowels in the wing holes. Position the
dowels so they protrude 1/2′′ out from the leading edge of the
wing. Let the epoxy cure before trying to insert the wing into the
fuselage.
Step 3. The fuselage wing hold-down holes are located toward
the rear of the fuselage wing opening. Note that the wing blind
nuts are already installed. You will not have to do anything with
these holes other than note their location.
Step 4. The two wing hold-down bolt holes are located near the
trailing edge of the wing. You will need to trim away the covering
with your hobby knife. Using a 1/4′′ drill bit, drill out the two
holes.
Section 4: Mounting the Wing
• Complete wing assembly
• Wing dowel rods (2)
• Fuselage Wing hold-down screws/washers (2)
Note: Blind nuts are already mounted
• Drill 1/4′′ drill bit
• Medium Phillips screwdriver
• Small round file
• Hobby knife
• 12-minute epoxy
• Measuring device (e.g., 36′′ ruler or tape measure)
• Masking tape
• Rubbing alcohol
• Paper towels
Parts Needed Tools and Adhesives Needed

19
Step 5. Once the wing dowels are dry, trial fit the wing to the
fuselage by inserting the leading edge of the wing into the dowel
holes in the fuselage and placing the wing trailing edge in its
relative position on the fuselage.
Note: Some trimming of the bolt holes may be necessary in
the following steps when the wing alignment is
checked.
Step 6. For a reference point, place a small piece of masking
tape centered on the bottom of the aft part of the fuselage. This
point will be the reference point to determine the wing alignment
in the next step.
Step 7. Bolt the wing to the fuselage. Turn the aircraft upside
down and, using a ruler, hold one end of the ruler on the
fuselage reference point you made, and the other end of the ruler
to one of the wing panel ailerons. Measure the distance. Next,
measure the distance of the other wing panel, using the
reference point to the other wing aileron, just as you did before.
Adjust the wing until you measure the same distance for both
wing panels. To make minor adjustments, you may have to
slightly enlarge the wing bolt holes with a small file.
CONTINUED
Section 4: Mounting the Wing

20
Step 1. Install the metal motor mount at this time. Trial fit the
mount to the fuselage firewall, noting that it mounts on its side.
The engine will have its cylinder pointing to the right as verified
by the pilot’s perspective when sitting in the cockpit. Once you
are satisfied with the proper orientation, attach the motor mount
to the firewall using the screws provided. Note there are blind
nuts installed in the firewall.
Step 2. After the motor mount is installed, install the side
windows. Examine the fuselage top carefully. Note the window
opening scribe marks on each side of the fuselage top. Trim out
the openings with a sharp hobby knife.
Caution: Use care to cut the opening. Final trim of the
opening can be done with a sanding stick
(medium/fine).
• Fuselage
• Plywood servo tray
• Front windshield
• Clear plastic sheet for side windows
• Motor mount
• Motor mount screws (4)
• Seats
• Canopy glue (e.g., R/C 56 or Pacer 256)
• 12-minute epoxy
• Masking tape
• Hobby knife with #11 blade
• Mixing sticks
• Epoxy brush
• Sanding stick (medium/fine)
• Measuring device (e.g., 36′′ ruler or tape measure)
• Scissors
• Rubbing alcohol
• Paper towel
Parts Needed Tools and Adhesives Needed
Section 5: Assembling the Fuselage