MotionRC OV-10 BRONCO User manual

Instruction Manual
OV-10 BRONCO
95% ALMOST READY TO FLY EP/GP
OPTIONAL ELECTRONIC RETRACTABLE LANDING GEAR (NOT INCLUDED).
INCLUDES OLEO STRUTS.
ALL BALSA - PLY WOOD CONSTRUCTION.
COVERED WITH ORACOVER.
SPECIFICATION:
- Wingspan:1,800 mm (70.87in).
- Length: 1,748mm (68.8 in).
- Weight: 6.8 - 7.1 kg (14.96 - 15.62 lbs).
- Wing area: 57.1dm2.
- Wing loading:119.1 g/dm2.
- Wing type: Naca Airfoil.
- Servo mount: 33mm x 17mm.
- Gear type: Eltronic retracts, 90 degree.
size: 81 x 44 x 29mm (not included).
Oleo struts (included).
- Spinner: 58mm (2pcs).
Parts Required (not included):
- Radio: 6 channels min,
(Admiral RX1000, 10ch Rx recommended).
- Servo: 45g Standard type (8pc),
(Hitec HS-485HB recommended).
- Engine: 40 - 46 2 stroke (2pcs) for nitro option.
- Motor : 35 - 42 size Brushless Outrunner Electric Motor (2pc),
(4S set-up, Admiral GP5 4220 770kv recommended)
(4S set-up, Tomcat G52 5025 590kv recommended) .
- Propeller: 12x8 2 blade (2pc).
- ESC: 65 - 85amp Brushless ESC (2pc),
(ZTW Mantis 65 recommended).
- Battery: 4S 4000 - 5000mah 14.8v 40 - 50C Lipo (2pc),
(Admiral 4000mah 4S 40C recommended)
6S 5000-6000mah 22.2v 40-50C Lipo,
(Admiral 5000mah 6S 50C recommended)
- Retracts: XWAVE RM400-90 recommended

INSTRUCTION MANUAL OV-10 BRONCO
2
Cut off excess.
BApply epoxy glue.
Apply threadlocker
(screw cement).
C.A
Apply instant glue
(C.A glue, super glue).
Cut off shaded portion
carefully.
Assemble left and right
sides the same way.
Must be purchased
separately!
Ensure smooth, non-binding
movement when assembling.
Warning!
Set all scerws securely. If they come off during
flight you will lose control of your aircraft!
Pay close attention here. Drill holes using the stated.
(in this case 1.5mm ).
1.5mm
Take particular care here.
The number of times
the same way Assembly
(in this case twice).
2
Symbols used throughout this instruction manual, comprise:
TABLE OF CONTENTS
►Symbols used throughout this instruction manual,
comprise.....................................................................2
► Warranty................................................................3
► Disclaimer..............................................................3
►Safety precaution...................................................3
►Important bulding notes.........................................3
►Suggestion.............................................................3
►Flight warnings......................................................3
►Covering tools........................................................4
►Adhesives and required tools................................4
►Academy of Model Aeronautics National Model
Aircraft Safety Code...................................................4
►Parts listing (not included).....................................6
►Tool & supplies needed.........................................6
►Preparation............................................................6
►Installing the ailerons and flaps..............................8
►Installing the ailerons and flaps servos...................8
►Installing the control horns and linkages...............10
►Rudder installation...............................................12
►Horizontal stabilizer installation............................16
►Installing the engine.............................................16
►Installing the stopper............................................18
►Installing the fuel tank..........................................19
►Installing the throttle.............................................20
►Installing the electric motor ( ep version )............21
►Installing the wheel well........................................23
►Installing the main gear.......................................25
►Installing the Electric gear retracts.......................26
►Installing the the nose gear..................................27
►Installing the cowling............................................30
►Installing the spinner............................................34
►Installing the Plastic parts for fuselage...............36
►Installing the receiver and battery........................36
►Installing the switch..............................................36
►Installing the Wing attachment, horizontal stabiliz-
er.............................................................37
►Installing the cockpit fuselage...............................39
►Balancing.............................................................41
►Lateral balance....................................................42
►Control throws.....................................................42
►Pre-flight check....................................................42
► For your radio installation basic connection for
airplane and adjustment of servos...........................43
► Main gear dimensional detail...............................44
►Decoration...........................................................45
►Exploded view.....................................................46
► I/C Flying warning................................................47

INSTRUCTION MANUAL OV-10 BRONCO
3
8 - 10 servos. Size: (32.3x16.8x31)mm.
Torque: 4.8V (3.89kg-cm), 6V (4.82 kg-cm).
BATTERY
LiPo. 4S Set-up:
2 x 14.8V 4000mAh
LiPo. 6S Set-up:
1 x 22.2v 6000mah
Retracts: XWAVE RM400-90
Size: (81 x 44 x 29)mm.
3 pcs.
Engine: 46.........2 pcs.
Propeller (2 pcs). Suit with your engine.
Servo extension leads.
................. 4 pcs.
................. 1 pcs.
190mm ...... 8 pcs.
330mm .... 10 pcs.
920mm ...... 1 pcs.
ESC
ESC: 65A ....... 2 pcs.
PARTS LISTING (NOT INCLUDED).
Wire cutters.
Hex Wrench.
Threadlocker
(screw cement).
Hand or
electric drill.
cm
12345678
910
Straight edge ruler.
Some more tools.
Assorted drill bits.
Masking tape.
Paper towels.
Rubbing alcohol.
90° square or builder's triangle.
Patients.
Screw driver
Medium C/A glue
EPOXY A
EPOXY B
30 minute epoxy.
5 minute epoxy.
Modeling knife.
2 bender plier
TOOLS & SUPPLIES NEEDED.
Use a covering iron
with a covering sock on hign
heat to tighten the covering if
necessary. Apply pressure
over sheeted areas to
thoroughly bond the covering
to the wood.
PREPARATIONS:
500mm ...... 2 pcs.
o
12AWG 200 C
4S Set-up Motor, 2 pcs:
Admiral GP5 4420-770kV
6S Set-up Motor, 2 pcs:
Tomcat G52 5025-590kV

INSTRUCTION MANUAL OV-10 BRONCO
4
2a
2b
4
6b
1b
5a
1c
5b
8
4mm Flat Washer
- - - - - - - 8
4mm Spring Washer
- - - - - - - 8
3x25mm Cap Screw
- - - - - 8
- - - - - 8
3mm Hex Nut
Size: 46
500mm Pushrod wire
- - - 2
- - - - - - 2
4x25mm Cap Screw
- - - - - 8
Connector
- - - - 2
14
14a
14b
16
16a 16b
3a
3b
3c
3
9
9a
9b
10c
10a
10b
10
- - - 4
- - 2
- - 2
7
3x15mm Tp Screw
11
12
13
14
15
16
:Fuselage ( 1a: Right fuselage, 1b: Left fuselage,
1c: Middle Fuselage).
: Wing panel (2a, 2b).
: Cockpit fuselage (3a:: Pilot, 3c: Cockpit).Canopy, 3b
: Horizontal stabilizer.
: Rudder (5a, 5b).
: Cowling (6a, 6b).
: Spinner (58mm).
: Aluminium wing dihedral brace.
Plastic parts of fuselage (9a, 9b).
:
: Wheel well (10a, 10b, 10c).
: Main gear struts (11a, 11b).
: Nose gear struts.
: Wheels (13a, 13b).
: Fuel Tank (14a: Clunk,
14b: Stopper (three line)).
: Wood - motor mount
: Plastic - engine mount (16a, 16b).
: Landing gear mount.
: Antenna.
: Plastic parts of wing (19a, 19b).
: Fiber glass part of middle fuselage.
1
2
3
4
5
6
7
8
7
9
10
6a
1a
17
18
19
20
18
19b
19a
20
- - - - - 2
4x60mm Socket Head
Cap Screw SIZE - 46
- - - - - 8
10x40mm Plastic
M3 Blind Nut
- - - - - 8
4mm Flat washer
- - - - - 8
4mm Spring Washer
- - - - - 8
4mm Flat washer
- - - - - 8
- - 8
3mm Spring Washer
- - - - - 8
3x15mm Cap Screw
- - - - - 8
15
100mm Push rod - - 5
- - - - - - 7
Flaslink
300mm Push rod - - 2
Horn - - - - 7
2x10mm Tp Screw
- - - - 28
3x12mm Tp Screw
- - - - 12
6x45mm Plastic screw
- - 2
4x20mm Plastic screw
- - - 2
5x30mm Socket Head
Cap Screw
M3 Metal Clevis
3x6mm Button Head
Cap Screw
- - - - - - - - 1
- - - - - - 3
3x15mm Cap Screw
- - - - 12
5mm Flat Washer
- - - - - - - - 3
350mm Cable
- - 2
- - - 2
- - - - 4
- - - 2
Cab link
Locknut
- - - - - - 2
3mm Hex Nut
45mm Aluminium
- - - - 2
12
13a
13b
17
11a
11b
75mm
65mm
3x10mm Tp Screw
- - - - 12
Nylon Clevis
1.7x8mm Cap Screw
- - - - - - 7
- - - - - - 7

INSTALLING THE AILERONS AND FLAPS.
INSTALLING THE AILERONS AND FLAPS SERVOS
2) Apply drops of thin CA to the top and bottom of
each hinge. Do not use CA accelerator. After the CA
has fully hardened, test the hinges by pulling on the
aileron.
Temporary pin to
keep hinge centered.
1) Test fit the ailerons to the wing with the hinges. If
the hinges don’t remain centered, stick a pin through
the middle of the hinge to hold it in position.
Flap
Flap
Bottom view
Aileron
B
1
2
C.A
C.A
Secure nylon hinges with instant glue, being
careful not to glue the wing and aileron together.
Align the center line of main wing with aileron.
1
2
Warning!
Make certain the hinges are
adequately secured with glue. if they come loose in
flight accidents may result.
1. Install the rubber grommets and brass eyelets
onto the aileron servos.
2. Using a modeling knife, remove the covering
from over the pre-cut servo arm exit hole on the
aileron servo tray / hatch. This hole will allow the
servo arm to pass through when installing the aileron
pushrods.
3. Place the servo into the servo tray. Center the
servo within the tray and drill 1.5mm pilot holes
through the block of wood for each of the four
mounting screws provided with the servo.
4. Using the thread as a guide and using masking
tape, tape the servo lead to the end of the thread:
carefully pull the thread out. When you have pulled
the servo lead out, remove the masking tape and the
servo lead from the thread.
5. Place the servo into the servo tray/ hatch into the
servo box on the bottom of the wing and drill 1.5mm
pilot holes through the tray and servo box for each of
the four mounting screws. Secure the servo tray in
place using the mounting screws provided.
6. Repeat step # 2 - # 5 to install the second aileron
servo in the opposite wing half.
INSTRUCTION MANUAL OV-10 BRONCO
5
Assemble left and right
sides the same way.
LR
BA Apply epoxy glue.
C
.
A
Apply instant glue
(C.A glue, super glue).
Ensure smooth, non-binding
movement when assembling.
Must be purchased
separately!
X

For Flap servo.
Bottom View
For Aileron servo.
2x10mm Tp Screw
- - - - 16
Warning!
Tie the string.
Pull out servo cord with string.
1
2
o
60
Flap
o
90
Aileron
approx.16mm
2mm
4
Aileron and
flap servos.
4
2x10mm Screw
2
For Flap.
For Aileron.
1.5mm
2 mm
2
For Flap.
For Aileron.
Screw
1.5mm
1.5mm
INSTRUCTION MANUAL OV-10 BRONCO
6
Bottom View
2x10mm Tp screw
2
1
For Aileron.
Assemble left and right
sides the same way.
LRCut off shaded portion
carefully.
The number of times
the same way Assembly
(in this case twice).
4
X
Drill holes using the stated.
(in this case 1.5mm ).
1.5mm

B
4
Horn
INSTALLING THE CONTROL HORNS AND LINKAGES
1) Working with the aileron linkage for now, thread
one nylon clevis at least 14 turns onto one of the
2mm x 180mm threaded wires.
2) Attach the clevis to the outer hole in the control
horn. Install a silicone tube on the clevis.
3) Locate one nylon servo arm, and using wire
cutters, remove all but one of the arms. Using a
2mm drill bit, enlarge the third hole out from the
center of the arm to accommodate the aileron
pushrod wire.
4) Plug the aileron servo into the receiver and
center the servo. Install the servo arm onto the
servo. The servo arm should be perpendicular to
the servo and point toward the middle of the wing.
5) Center the aileron and hold it in place using a
couple of pieces of masking tape.
6) With the aileron and aileron servo centered,
carefully place a mark on the aileron pushrod wire
where it crosses the hole in the servo arm.
7) Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess wire,
leaving about 6mm beyond the bend.
8) Insert the 90 degree bend down through the
hole in the servo arm. Install one nylon snap
keeper over the wire to secure it to the arm. Install
the servo arm retaining screw and remove the
masking tape from the aileron.
9) Repeat step # 4 - # 8 to install the second
aileron linkage. After both linkages are completed,
connect both of the aileron servo leads using a Y-
harness you have purchased separately.
Bottom view
Bottom view
INSTRUCTION MANUAL OV-10 BRONCO
7
Assemble left and right
sides the same way.
LR
BA Apply epoxy glue.
Cut off shaded portion
carefully.
The number of times
the same way Assembly
(in this case twice).
4
X
100mm Push rod - - 4
Nylon Clevis
1.7x8mm Cap Screw
- - - 4
- - - 4
Horn - - - - - - 2
- - - - - - 2
Flaslink

Bottom view
Mark the spot to attach
1
2
Bend 90o
Flaslink
Push rod
4
2
Servo arm
6mm
1
INSTRUCTION MANUAL OV-10 BRONCO
8
Cut off excess. The number of times
the same way Assembly
(in this case twice).
4
X
Assemble left and right
sides the same way.
LR
Control Horn
4

INSTRUCTION MANUAL OV-10 BRONCO
9
RUDDER INSTALLATION
1) Rudder are installed the same way as the aileron
before.
2) Control horn, linkages for rudder are installed the
same way as the elevator before.
Temporary pin to
keep hinge centered.
1) Test fit the ailerons to the wing with the hinges. If
the hinges don’t remain centered, stick a pin through
the middle of the hinge to hold it in position.
2) Apply drops of thin CA to the top and bottom of
each hinge. Do not use CA accelerator. After the CA
has fully hardened, test the hinges by pulling on the
aileron.
12
C.A
C.A
Secure nylon hinges with instant glue, being
careful not to glue the wing and aileron together.
Align the center line of main wing with aileron.
1
2
Warning!
Make certain the hinges are
adequately secured with glue. if they come loose in
flight accidents may result.
LR
2
X
C
.
A
Apply instant glue
(C.A glue, super glue).
Ensure smooth, non-binding
movement when assembling.
The number of times
the same way Assembly
(in this case twice).
2
X
Assemble left and right
sides the same way.
LR
300mm Push rod - - 2
Horn - - - - 2
- - - - 2
Flaslink
2x10mm Tp Screw
- - 8
Nylon Clevis
1.7x8mm Cap Screw
- - - 1
- - -1

INSTRUCTION MANUAL OV-10 BRONCO
10
o
90
approx.16mm
2mm
22
2x10mm Screw
2
1.5mm
2 mm
2
Screw
1.5mm
1.5mm
Assemble left and right
sides the same way.
LR
The number of times
the same way Assembly
(in this case twice).
2
X
For Rudder Servos
LR
2
X
Drill holes using the stated.
(in this case 1.5mm ).
1.5mm
Cut off shaded portion
carefully.
Pay close attention here.

INSTRUCTION MANUAL OV-10 BRONCO
11
The number of times
the same way Assembly
(in this case twice).
2
X
Cut off shaded portion
carefully.
LR
2
X
Horn
B
2
Horn
LR
2
X
BA Apply epoxy glue.
Assemble left and right
sides the same way.
LR

INSTRUCTION MANUAL OV-10 BRONCO
12
Mark the spot to attach
1
2
Bend 90o
Flaslink
Push rod
2
2
Servo arm
6mm
6mm
1
Cut off excess.
2
X
The number of times
the same way Assembly
(in this case twice).
2
X
Assemble left and right
sides the same way.
LR
LR
Control Horn

INSTALLING THE ENGINE
* Locate the long piece of wire used for the throttle
pushrod. One end of the wire has been pre-bend in to
a "Z" bend at the factory. This "Z" bend should be
inserted into the throttle arm of the engine when the
engine is fitted onto the engine mount. Fit the engine
to the engine mount using the screws provided.
3mm Flat washer
3x25mm Cap Screw
- - - - - - - 8
4mm Spring Washer
- - - - - - - 8
- - - - - 8
- - - - - 8
3mm Hex Nut
Size-46
Engine mount
500mm Pushrod wire
- - - 2
4x25mm Cap Screw
- - - - - 8
4mm Flat Washer
- - - - - - - 8
INSTRUCTION MANUAL OV-10 BRONCO
13
INSTALLING HORIZONTAL STABILIZER
1) Hinges and servo for Elevator are glued the
same way as the aileron before (see page 8, 9).
2) Control horn and linkages for Elevator are
installed the same way as the aileron before
(see page 10, 11). 2x10mm
Bottom View
Bottom View
100mm Push rod
- - 1
Horn
- - - - - 1
- - - - - 1
- - - - - 4
Flaslink
2x10mm Tp Screw
Nylon Clevis
1.7x8mm Cap Screw
- - - 1
- - -1

Secure
4mm Spring Washer
4mm Flat Washer
4x25mm Cap Screw
3x25mm Cap Screw
3mm Flat Washer
3mm Hex Nut
INSTRUCTION MANUAL OV-10 BRONCO
14
Pushrod wire
The number of times
the same way Assembly
(in this case twice).
2
X
Assemble left and right
sides the same way.
LR
2
X
LR
2
X
LR
Top View
2
X
LR

115mm
INSTRUCTION MANUAL OV-10 BRONCO
15
Rubber
Rubber
Aluminum
Aluminum
30mm Screw
INSTALLING THE STOPPER
The number of times
the same way Assembly
(in this case twice).
2
X
Assemble left and right
sides the same way.
LR
2
X
LR
Top View

INSTRUCTION MANUAL OV-10 BRONCO
16
Cut off shaded portion
Bend 40
0
degree
Bend 40
0
degree
40 degree bend
40
0
40
0
9mm 12mm
6mm
!
Inflame
Do not overheat,
it may break.
WARNING
!
1. Using a modeling knife, cut one length of silicon
fuel line (the length of silicon fuel line is
calculated by how the weighted clunk should
rest about 5mm away from the rear of the tank
and move freely inside the tank). Connect one
end of the line to the weighted clunk and the
other end to the nylon pick up tube in the
stopper.
2. Carefully bend the second nylon tube up at a 45
degree angle (using a cigarette lighter). This
tube will be the vent tube to the muffler.
3. Carefully bend the third nylon tube down at a 45
degree angle (using a cigarette lighter). This
tube will be vent tube to the fueling valve.
When the stopper assembly is installed in the
tank, the top of the vent tube should rest just
below the top surface of the tank. It should not
touch the top of the tank.
4. Test fit the stopper assembly into the tank. It
may be necessary to remove some of the
flashing around the tank opening using a
modeling knife. If flashing is present, make
sure none of it falls into the tank.
!
5. When satisfied with the alignment of the stopper
assembly tighten the 3mm x 20mm machine
screw until the rubber stopper expands and
seals the tank opening. Do not over tighten the
assembly as this could cause the tank to split.
6. Using a modeling knife, cut 3 lengths of fuel line
. Connect 2 lines to the 2 vent tubes and 1 line
to the fuel pickup tube in the stopper.
7. Feed three lines through the fuel tank
compartment and through the pre-drilled hole in
the firewall. Pull the lines out from behind the
engine, while guiding the fuel tank into place.
Push the fuel tank as far forward as possible,
the front of the tank should just about touch the
back of the firewall.
Blow through one of the lines to ensure the fuel
lines have not become kinked inside the fuel
tank compartment. Air should flow through
easily.
Do not secure the tank into place permanently
until after balancing the airplane. You may
need to remove the tank to mount the battery in
the fuel tank compartment.
8. Secure the fuel tank.
INSTALLING THE FUEL TANK

INSTRUCTION MANUAL OV-10 BRONCO
17
Zip tie
Fuel Tank
Tygon Tubing
Fuel Tank
1) Install one adjustable metal connector through the
third hole out from the center of one servo arm,
enlarge the hole in the servo arm using a 2mm drill bit
to accommodate the servo connector. Remove the
excess material from the arm.
After installing the adjustable metal connec-
tor apply a small drop of thin C/A to the bottom
nut. This will prevent the connector from loosen-
ing during flight.
2) Plug the throttle servo into the reveiver and turn
on the radio system. Check to ensure that the throttle
servo output shaft is moving in the correct direction.
When the throttle sick is moved forward from idle to
full throttle, the throttle barrel should also open and
close using this motion. If not, reverse the direction of
the servo, using the transmitter.
INSTALLING THE THROTTLE
3) Slide the adjustable metal connector / servo arm
assembly over the plain end of the pushrod wire.
Position the throttle stick and the throttle trim at their
lowest positions.
4) Manual push the carburator barrel fully closed.
Angle the arm back about 45 degree from center and
attach the servo arm onto the servo. With the carbura-
tor barrel fully closed, tighte the set screw in the
adjustable metal connector.
5) Remove the excess throttle pushrod wire using
wire cutters and install the servo arm retaining screw.
- - - - - - - - - - - - 1
Connector
Adjust the throttle input (transmitter
throttle stick), throttle trim movement
and the carburattor opening to the
suitable position and screw in the
4x4mm set scew.
Top View
The number of times
the same way Assembly
(in this case twice).
2
X
2
X
Assemble left and right
sides the same way.
LR
LR
- - - - - - - - - - - 2
- - - - - - - - - - - 2
- - - - - - - - - - - 2
Clunks
Stopper (three line)

M3 Blind Nut
3mm Spring Washer
3x15mm Cap Screw
2
o
90
approx.16mm
2mm
Linkage stopper
4x4mm
2x10mm
2mm
Pushrod wire
Adjust the throttle input
(transmitter throttle stick),
throttle trim movement and the
carburattor opening to the
suitable position and screw in
the 4x4mm set screw.
2
Throttle servo
Fuel tank
INSTALLING THE ELECTRIC MOTOR (EP VERSION)
- - - - - 8
10x40mm Plastic
M3 Blind Nut
- - - - - 8
4mm Flat Washer
- - - - - 8
4mm Spring Washer
- - - - - 8
4mm Flat Washer
- - - - - 8 - - - - - 2
- - 8
4x60mm Socket Head
Cap Screw
3x15mm Cap Screw
- - - - - 8 3mm Spring Washer
- - - - - 8
INSTRUCTION MANUAL OV-10 BRONCO
18
Screw
Apply threadlocker
(screw cement).
Must be purchased
separately!
X
SIZE - 46
The number of times
the same way Assembly
(in this case twice).
2
X
Assemble left and right
sides the same way.
LR
LR
2
LR
Wood - motor mount
Ensure smooth, non-binding
movement when assembling. Drill holes using the stated.
(in this case 2mm ).
2mm
Top View

2
2
INSTRUCTION MANUAL OV-10 BRONCO
19
Must be purchased
separately!
X
4x60mm Socket Head
Cap Screw
4mm Spring Washer
4mm Flat Washer
4mm Flat Washer
The number of times
the same way Assembly
(in this case twice).
2
X
10x40mm Plastic
115mm
Assemble left and right
sides the same way.
LR
LR
LR
Top View
Top View
Top View

INSTALLING THE WHEEL WELL
Fuselage Bottom Side
2
C.A
2
* Using a modeling knife, carefully
remove the film covering from the
f gear tray. Make sure that you douselage
not remove any wood.
WHEEL WELL
5mm
5mm
Cut the plastic
Cut the plastic
INSTRUCTION MANUAL OV-10 BRONCO
20
The number of times
the same way Assembly
(in this case twice).
2
X
Assemble left and right
sides the same way.
LR
LR
LR
C
.
A
Apply instant glue
(C.A glue, super glue).
Cut off shaded portion
carefully.
Bottom View