Hangar 9 Ultra Stick 40 ARF User manual

Specications
Wingspan: ..........................................................57.75 in (1467mm)
Length: ................................................................... 51 in (1295mm)
Wing Area: ................................... 700 sq in (715 with quad aps)
Weight: .............................................................. 5–6 lb (2.3–2.7 kg)
Radio: ............................................................4-channel or greater
Engine: ..................................... .40–.46 2-stroke, .56–.82 4-stroke
Ultra Stick™40 ARF
Assembly Manual

2 Hangar 9 Ultra Stick 40 ARF Assembly Manual
Large Replacement Parts
1. HAN173001 Fuselage
2. HAN173002 Wing Set with Standard Ailerons
3. HAN173003 Tail Set
4. HAN173004 Quad Flaps
5. HAN173005 Aluminum Main Landing Gear
6. HAN173006 Nose Wheel Strut with Wheel
7. HAN173007 Spinner 21/4-inch, Red
8. HAN173009 Pushrod Set
9. HAN173010 Engine Mount
10. HAN173013 Wheels 21/2-inch (2)
11. HAN4709 Tail Wheel Assembly
Small Replacement Parts (not shown)
HAN173008 Decal Sheet
HAN173011 Fuel Tank 11 oz (320cc)
HAN173012 Wheel Axles
Contents of Kit and Parts Layout
1
2
2
4
3
3
810
5
6
11
9
7
Table of Contents
Contents of Kit and Parts Layout ...........................................2
Included Parts Listing............................................................3
Using the Manual...................................................................4
Important Information Regarding Warranty Information .......4
UltraCote Covering Colors .....................................................4
Before Starting Assembly ......................................................4
Radio System Requirements .................................................4
Optional Items for Quad Flaps Installation.............................4
Recommended Setup–2-Stroke Glow....................................4
Recommended Setup–4-Stroke Glow....................................4
Field Equipment Required......................................................4
Optional Field Equipment.......................................................4
Tools and Supplies.................................................................4
Additional Required Adhesives ..............................................4
Aileron Installation (Aileron Only)..........................................5
Aileron and Flap Installation(Quad Flap Only)........................7
Joining the Wing Panels ........................................................9
Completing the Wing Assembly...........................................11
Horizontal Stabilizer Installation...........................................13
Vertical Fin Installation.........................................................14
Preparation for Tail Gear Installation....................................15
Rudder Installation...............................................................16
Elevator Installation .............................................................18
Radio Installation.................................................................19
Aileron Servo Installation(Aileron only) or
Flap Servo Installation (Quad Flap Version)...................22
Aileron Servo Installation(Quad Flap Version) .....................25
Landing Gear Installation.....................................................28
Engine Installation ...............................................................30
Nose Gear Installation..........................................................34
Fuel Tank Assembly .............................................................36
Throttle Pushrod Connection and Fuel Tank Installation......38
Final Radio Installation.........................................................40
Center of Gravity..................................................................41
Control Throws ....................................................................41
Quad Flaps...........................................................................42
Flight Preparations...............................................................43
Safety Do’s and Don’ts for Pilots .........................................44
Daily Flight Checks...............................................................44
Safety, Precautions and Warnings .......................................44
Warranty Information...........................................................45
Instructions for Disposal of WEEE by
Users in the European Union.........................................46
2009 Official Academy of
Model Aeronautics Safety Code.....................................47

3Hangar 9 Ultra Stick 40 ARF Assembly Manual
PCKAGED IN BOX
Fuselage (1)
Right wing with aileron (1)
Left wing with aileron (1)
Horizontal stabilizer with elevator (1)
Vertical fin with rudder (1)
Right quad flap set (1)
Left quad flap set (1)
LINKAGES AND CONTROL HARDWARE
Nylon clevis (6) Ailerons, flaps, rudder and
elevator
90-degree snap link (6) Ailerons, flaps, rudder and
elevator
Clevis retainer tubing (6) Ailerons, flaps, rudder and
elevator
CA hinges (16) Ailerons, flaps, rudder and
elevator
2mm x 271/2-inch pushrod (2) Elevator and rudder
2mm x 6-inch pushrod (4) Aileron and flap
Pushrod guide tube (2) Throttle and steering
2mm x 16mm machine screw (12) Control horns
Nylon control horn with backplate (6) Ailerons, flaps, rudder and
elevator
Pushrod support tab (1) Nose wheel pushrod support
FUEL TANK
11 oz (320cc) fuel tank (1)
Silicone fuel line (red, green, clear) (1) Fuel tank
Tank stopper (1) Fuel tank
Metal backing plate disk (2) Fuel tank
3mm machine screw (1) Tank
Clunk (1)
Aluminum tubing (3) Vent, fill and overflow
Balsa block (1) Fuel tank
LANDING GEAR
4mm wheel axles (2) Main wheels
8-32 x 5/8-inch Phillips machine screw (2) Landing gear to fuselage
#8 flat washer (2) Landing gear to fuselage
Pushrod connector with back and setscrew (2) Throttle and steering
1.5mm x 173/4-inch pushrod (2) Throttle & steering
Aluminum landing gear (1) Main landing gear
21/2-inch (64mm) rubber wheels (3) Main landing gear and nose
wheel option
Tail wheel wire with nylon bracket (1)
1-inch wheel (1) Tail wheel
2mm wheel collar (1) Tail wheel
4mm wheel collar (8) Main landing gear and nose gear
4mm nose gear wire strut (1) Tricycle gear option
Nose gear steering arm (1) Tricycle gear option
ENGINE MOUNT
Nylon engine mount (2)
21/4-inch red plastic spinner with screws (1)
#8 silver flat washers (4) Engine to mount and mount to
firewall
8-32 x 1-inch socket head screws (4) Motor mount to firewall and
engine to mount
6-32 x 1 in socket head screw (4) Engine to mount
6-32 lock nuts (4) Engine to mount
#6 Flat washer (4) Engine to mount
WING ASSEMBLY AND INSTALLATION
Nylon 1/4-20 x 11/2-inch wing bolts (2) Wing to fuselage
Wing bolt washer plate (1)
2 x 1/4-inch dowel rods (2) Anti-rotation pins
Hardwood wing spar (1)
1-inch white covering strip (1) Center wing joint
Included Parts Listing

4 Hangar 9 Ultra Stick 40 ARF Assembly Manual
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 each step completed.
Steps with a single box () are performed once, while steps
with two boxes () indicate that 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.
Important Information
Regarding Warranty Information
Please read our Warranty and Liability Limitations section on
Page 45 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.
UltraCote® Covering Colors
• Black HANU874
• White HANU870
• True Red HANU866
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 or
covering iron to remove them. Use caution while working
around areas where the colors overlap to prevent separating
the colors.
HAN100 – Heat Gun
HAN150 – Covering Glove
HAN101 – Sealing Iron
HAN141 – Sealing Iron Sock
Radio System Requirements
Spektrum Radio System (recommended)
• DX6i 6-channel radio or greater with receiver
(SPM6600)
• DS821 Digital Sport Servo (5) (JRPS821)
• Y-Harness (JSP98020) or 3-inch Servo Extension (2)
(JSP98100) for receiver to aileron servo extensions
• Receiver Battery, 2300mAh 5-cell (JRPB5006)
• JR Switch, Chargeswitch (JRPA004)
Optional Items for
Quad Flaps Installation
• DS821 Digital Sport Servo (JRPS821)
• DS821 Digital Sport Servo, Reverse (JRPS821R)
• 3-inch Servo Extension (2) (JSP98100) for receiver to
servo extensions
• 9-inch Servo Extension (2) (JRPA097) for servo to
servo extensions inside wing
Recommended Setup–2-Stroke Glow
• Evolution® .46NX with Muffler (EVOE0461)
• Evolution Propeller 11 x 5 (EVO11050) or
11 x 6 (EVO11060)
• Exhaust Diverter (DUB697) (optional)
Recommended Setup–4-Stroke Glow
• Saito™.82 AAC with Muffler (SAIE082A or SAIE082AGK)
• Evolution Propeller 13 x 8 (EVO13080) or
14 x 6 (EVO14060)
• Exhaust Diverter (DUB697) (optional)
Field Equipment Required
• Fuel (15% recommended)
• Propeller
• Long Reach Glow Plug Wrench (HAN2510)
• Metered Glow Driver with Ni-Cd & Charger (HAN7101)
• 2-Cycle Sport Plug (EVOGP1)
• Manual Fuel Pump (HAN118)
Optional Field Equipment
• Selfstick Weights, 6 oz (HAN3626)
• PowerPro 12V Starter (HAN161)
• 12V 7Ah Sealed Battery (HAN102)
• Power Panel (HAN106)
• Blue Block After Run Oil (EVOX1000)
• Cleaner and towels
Tools and Supplies
Drill Epoxy brush
Felt-tipped pen Hook and loop tape
Hobby knife with #11 blade Low-tack tape
Sandpaper Mixing cup
Mixing stick Paper towel
Phillips screwdriver: #1, #2 Pencil
Pin vise Pliers
Rotary tool Rubbing alcohol
Ruler Diagonal cutters
String Threadlock
T-pin Sanding drum
Foam rubber, 1/4-inch (6mm)
Nut driver or box wrench: 1/4-inch
Box wrench to fit propeller nut
Box end or open end wrench: 10mm (2)
Hex wrench or ball driver: 1.5mm, 2.5mm, 3/32-inch,
9/64-inch
Drill bit: 1/16-inch (1.5mm), 5/64-inch (2mm), 1/8-inch
(3mm), 5/32-inch (4mm), 11/64-inch (4.5mm),
7/32-inch (5.5mm)
Additional Required Adhesives
30-Minute Epoxy (HAN8002)
Medium CA (PAAPT02)
Thin CA (PAAPT08)
The Spektrum trademark is used with permission
of Bachmann Industries, Inc.

5Hangar 9 Ultra Stick 40 ARF Assembly Manual
Aileron Installation (Aileron Only)
Required Parts
Wing panel (right and left)
Aileron, full length (right and left)
CA hinge (8)
Tools and Adhesives
Drill bit: 1/16-inch (1.5mm) Pin vise
Hobby knife with #11 blade Thin CA
Note: There are two wing configurations for your
model, standard two ailerons and quad flaps (ailerons
with flaps). This section covers the installation of the
ailerons for the two aileron versions of your model.
 Step 1
Check to make sure you have the correct aileron. The trim will
match the bottom of the wing.
 Step 2
Use a pin vise and 1/16-inch (1.5mm) drill bit to drill a hole in
the center of each hinge slot. Drill holes for both the aileron
and wing.
 Step 3
Place a T-pin in the center of each hinge. Insert the hinges in
the slots in the trailing edge of the wing. Try to align the slot in
the hinge with the hole drilled in the previous step.

6 Hangar 9 Ultra Stick 40 ARF Assembly Manual
 Step 4
Use the hinges to place the aileron in position. Use a hobby
knife to set the gap between the control surface and the wing.
Also check that the aileron can move freely without rubbing at
the wing tip.
 Step 5
Saturate each of the hinges with thin CA. Make sure to glue
both the top and bottom. Once the CA has cured, gently pull
on the aileron to make sure the hinges are secure. If not, apply
more CA to the loose hinge.
Note: Do not use CA accelerator on the hinges. The CA
must be allowed to soak into the hinge and surrounding
wood.
 Step 6
Flex the aileron up and down a number of times to break in
the aileron hinges.
Step 7
Repeat Steps 1 through 6 to install the remaining aileron.

7Hangar 9 Ultra Stick 40 ARF Assembly Manual
Aileron and Flap Installation
(Quad Flap Only)
Required Parts
Wing panel (right and left) Aileron (right and left)
Flap (right and left) CA hinge (8)
Tools and Adhesives
Drill bit: 1/16-inch (1.5mm) Pin vise
Hobby knife with #11 blade Thin CA
 Step 1
Check to make sure you have the correct aileron. The trim will
match the bottom of the wing.
Note: The flap and aileron have not been seperated at
this time and are still taped together as shipped.
 Step 2
Use a pin vise and 1/16-inch (1.5mm) drill bit to drill a hole in
the center of each hinge slot. Drill holes for both the aileron
and wing. Also prepare the flap at this time.
 Step 3
Place a T-pin in the center of each hinge. Insert the hinges in
the slots in the trailing edge of the wing. Try to align the slot in
the hinge with the hole drilled in the previous step.

8 Hangar 9 Ultra Stick 40 ARF Assembly Manual
 Step 4
Use the hinges to place the aileron in position. Use a hobby
knife to set the gap between the control surface and the wing.
Also check that the aileron can move freely without rubbing at
the wing tip.
 Step 5
Saturate each of the hinges with thin CA. Make sure to glue
both the top and bottom. Once the CA has cured, gently pull
on the aileron to make sure the hinges are secure. If not, apply
more CA to the loose hinge.
 Step 6
Flex the aileron up and down a number of times to break in
the aileron hinges.

9Hangar 9 Ultra Stick 40 ARF Assembly Manual
 Step 7
Installing the flap follows the same procedure as the aileron.
Position the flap, check the gap and that it doesn’t hit the
aileron and apply CA. Make sure to check the hinges and
break them in.
Step 8
Repeat Steps 1 through 7 to attach the remaining aileron and
flap to the wing.
Joining the Wing Panels
Required Parts
Wing panel (right and let) Wing joiner
Tools and Adhesives
30-minute epoxy Epoxy brush
Mixing stick Mixing cup
Paper towel Rubbing alcohol
Low-tack tape Waxed paper
Step 1
Mark the wing joiner and wing panel using a felt-tipped pen.
This is so you can orient the joiner correctly in this section of
the manual.

10 Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 2
Mark a center line on the joiner. It should slide into each wing
panel up to the line. If not, lightly sand the joiner so it fits
correctly.
Step 3
Use 30-minute epoxy to glue the joiner into the wing panels.
Apply epoxy in the joiner pocket and all sides of the joiner,
including the top and bottom edges. Also coat the exposed
wood on the root rib with epoxy. Start with one panel, insert
the joiner, then the opposite panel.

11Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 4
Make sure the wing panels fit tightly together. Clean any epoxy
using a paper towel and rubbing alcohol. Use low-tack tape to
keep the panels tightly together while the epoxy cures.
Important: Make sure the leading edge and trailing
edges of the wing at the joint are aligned with each
other.
Note: The wing has no dihedral. It will rest flat on
your work surface while the epoxy cures. Make sure to
cover your work surface with waxed paper so you don’t
accidentally glue the wing to your work surface.
Completing the Wing Assembly
Required Parts
Assembled wing Wing bolt plate
Covering Wing dowel (2)
Tools and Adhesives
Hobby knife with #11 blade Felt-tipped pen
Covering iron 30-minute epoxy
Low-tack tape Ruler
Step 1
Use a hobby knife to remove the covering to expose the holes
in the wing bolt plate. Also remove the covering from one
side of the plate. Leave a 1/16-inch (1.5mm) edge of covering
around the perimeter as shown in the second photo.

12 Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 2
Position the wing bolt plate on the wing, aligning the holes
with those in the wing. Trace the outline of the plate onto the
wing using a felt-tipped pen. Use a hobby knife and #11 blade
to trim the covering from the wing 1/16-inch (1.5mm) inside
the line drawn.
Step 3
Use 30-minute epoxy to glue the wing bolt plate to the wing.
Use low-tack tape to keep the plate secure while the epoxy
cures. Use a covering iron to apply the covering over the seam
between the wing panels.
Step 4
Use 30-minute epoxy to glue the wing dowels in the leading
edge of the wing. Position them so they protrude 1/2-inch
(13mm) from the leading edge.
Hint: Add a radius to the front edge of the dowels to
make it easier to install them in the fuselage.

13Hangar 9 Ultra Stick 40 ARF Assembly Manual
Horizontal Stabilizer Installation
Required Parts
Fuselage Wing assembly
Stabilizer
1/4-20 x 11/2-inch nylon wing bolt (2)
Tools and Adhesives
Ruler Felt-tipped pen
Hobby knife with #11 blade T-pin
30-minute epoxy Flat blade screwdriver
Rubbing alcohol Paper towels
Mixing cup Epoxy brush
Mixing stick
Step 1
Install the wing by aligning the dowels from the wing into the
holes in the fuselage.
Step 2
Secure the wing using two nylon wing bolts. Tighten the bolts
using a flat blade screwdriver.
Step 3
Use a ruler to mark the center of the stabilizer. Do not use the
covering as a guide as it may not be centered. Use a T-pin at
the rear of the stabilizer as a pivot and to keep the stabilizer in
position on the fuselage.
Step 4
Check the alignment of the stabilizer to the wing. Position the
stabilizer so the measurements from the stabilizer tips to the
wings tips is equal. Also check that the stabilizer is parallel to
the wing. Lightly sand the stabilizer saddle if adjustments are
required.
A
A=A
Parallel

14 Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 5
Use a felt-tipped pen to trace the outline of the fuselage on
the stabilizer. Use a hobby knife and #11 blade to remove
the covering from the center of the stabilizer 1/16-inch
(1.5mm) inside the line drawn. Use 30-minute epoxy to glue
the stabilizer to the fuselage. Use a paper towel and rubbing
alcohol to remove any excess epoxy before it has a chance to
fully cure. Allow the epoxy to cure before proceeding.
Note: Do not press on the knife when cutting the
covering. Cutting into the wood of the stabilizer will
weaken it and cause it to fail in flight.
Vertical Fin Installation
Required Parts
Fuselage Vertical fin
Tools and Adhesives
Square Felt-tipped pen
Hobby knife with #11 blade 30-minute epoxy
Step 1
Insert the fin in the slot at the rear of the fuselage. Use a felt-
tipped pen to trace the outline of the fuselage on the area of
the fin that fits into the fuselage. Also trace the outline of the
fin on the top of the fuselage. Step 2
Use a hobby knife and #11 blade to remove the covering from
the fuselage and fin. Trim the covering 1/16-inch (1.5mm)
inside the lines drawn on the fuselage, and 1/16-inch (1.5mm)
below the line on the fin.

15Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 3
Use 30-minute epoxy to glue the fin to the fuselage. Use a
square to check the alignment of the fin to the stabilizer while
the epoxy cures to make sure it is aligned properly.
Hint: Use low-tack tape to hold the vertical fin in
position until the epoxy fully cures.
Preparation for Tail Gear Installation
Required Parts
Rudder Tail gear wire
Tools and Adhesives
Pin vise Drill bit: 1/8-inch (3mm)
Felt-tipped pen Ruler
30-minute epoxy Petroleum jelly
Hobby knife with #11 blade Sandpaper
Note: This section covers preparing the rudder for the
tail gear wire. If you are building the tricycle version
of this model, you can skip to the next section of the
manual.
Step 1
Measure up 7/8-inch (22mm) from the bottom of the rudder
and mark it using a felt-tipped pen. Use a pin vise and 1/8-
inch (3mm) drill bit to drill a hole that is 1-inch (25mm) deep
in the rudder.
Step 2
Use a hobby knife and #11 blade to cut a groove from the hole
in the rudder to the bottom of the rudder for the bearing on
the tail gear wire to fit into.

16 Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 3
Lightly sand the end of the wire that will fit into the rudder.
Apply a small amount of petroleum jelly to the top and bottom
of the bearing to keep epoxy from entering the bearing.
Step 4
Insert the tail gear wire into the rudder. It should fit as shown.
Use 30-minute epoxy to glue only the wire entering the rudder
into the fin.
Rudder Installation
Required Parts
Fuselage assembly Rudder assembly
CA hinge (2)
Tools and Adhesives
Drill bit: 1/16-inch (1.5mm) Pin vise
Hobby knife with #11 blade Thin CA
T-pins
Step 1
Use a pin vise and 1/16-inch drill bit to drill a hole in the
center of each hinge on both the fin and rudder.

17Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 2
Insert a T-pin in the center of the two CA hinges. Slide the
hinges into the fin.
Note: If you are installing the tail wheel, it will be
necessary to enlarge the slot at the bottom of the fin to
fit the tail gear bushing as shown below.
Step 3
Fit the rudder to the fin. Use a hobby knife and #11 blade to
check the hinge gap and that the rudder is not rubbing the top
of the fin.
Note: If you are installing the tail wheel, use 30-minute
epoxy to glue the tail gear bushing into the fuselage.
Step 4
Use thin CA to glue the two hinges that secure the rudder and
fin. Perform a pull test on the hinges and break them in at this
time.

18 Hangar 9 Ultra Stick 40 ARF Assembly Manual
Elevator Installation
Required Parts
Fuselage assembly CA hinge (6)
Elevator
Tools and Adhesives
Drill bit: 1/16-inch (1.5mm) Pin vise
Thin CA T-pins
Rotary tool with sanding drum (optional)
Felt-tipped pen (optional)
Note: This first step is only necessary if you are
installing the tail wheel. If you are building the tricycle
version, skip to Step 2.
Step 1
Position the elevator against the stabilizer. Use a felt-tipped
pen to mark where the tail wheel wire rests against the
elevator. Use a rotary tool and sanding drum to make a notch
so the elevator does not bind against the wire.
Step 2
Use a pin vise and 1/16-inch (1.5mm) drill bit to drill a hole in
the center of each hinge slot in the stabilizer and elevator.
Step 3
Insert a T-pin in the center of the six stabilizer hinges. Insert
the hinges in the elevator as shown.

19Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 4
Install the elevator against the stabilizer using the hinges. Set
the hinge gap using a hobby knife and #11 blade. Saturate
each hinge using thin CA. Allow the CA to fully cure before
checking the hinges.
Step 5
Flex the elevator up and down a number of times to break in
the hinges.
Radio Installation
Required Parts
Fuselage assembly Servo with hardware (3)
Control horn (2) Control horn backplate (2)
Clevis retainer (2) Clevis (2)
Pushrod keeper (2) Screw lock connector
2-56 x 5/8-inch machine screw (4)
Pushrod wire, 275/8-inch (700mm) (2)
Tools and Adhesives
Phillips screwdriver: #1 Thin CA
Pliers Diagonal cutter
Drill bit: 5/64-inch (2mm) Pin vise
Threadlock Felt-tipped pen
Step 1
Use a #1 Phillips screwdriver to thread a servo mounting
screw into each of the holes in the servo tray. Apply 2–3 drops
of thin CA in each hole to harden the surrounding wood.

20 Hangar 9 Ultra Stick 40 ARF Assembly Manual
Step 2
Use the hardware to mount the servos in the fuselage as
shown. Slide a 275/8-inch (700mm) pushrod wire into the
tube near the rudder servo. The wire will exit near the rudder
as shown. Use a hobby knife and #11 blade to trim the
covering so the wire can exit the fuselage.
Step 3
Slide a clevis retainer on a clevis, then thread the clevis
12-turns on the pushrod wire. Connect the clevis to the
control horn as shown. With the holes in the control horn
aligned with the hinge line, use a felt-tipped pen to mark the
mounting locations for the control horn mounting screws.
Step 4
Use a pin vise and 5/64-inch (2mm) drill bit to drill the holes
for the screws. Use 2–3 drops of thin CA to harden the holes.
Secure the control horn to the rudder using two 2-56 x 5/8-
inch machine screws and a control horn backplate.