Phoenix Model Dolphin 40 User manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
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Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
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Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
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Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual

INTRODUCTION
Thank you for choosing the new Dolphin 40 ARF by Phoenix Model. The Dolphin 40 was designed from
the ground up with the intermediate sport flyer in mind. It is a low wing sport aerobatic aircraft that is easy to
fly and quick to assemble, yet is capable of aerobatics to please even the best sport pilot. The airframe is
conventionally built using balsa, plywood and veneer to make it stronger than the average ARF kit, yet the
design allows the aircraft to be built light as well. You will find that most of the work has been done for you
already. The pushrods are premade to the correct lengths, the motor mount has been installed and even the
hinges are preinstalled and pinned for security. Flying the Dolphin 40 is simply a joy too. It's constant cord
wings make landing a breeze without the bad habits of other aerobatic planes and it's generous stabilizer
area keeps it tracking straight and true.
The Dolphin 40 ARF is an easy flying sport airplane, however, it may not be appropriate for some first time
modelers. If you have chosen the Dolphin 40 ARF as your first airplane, we recommend you seek
assistance from an experienced modeler.
We know you'll enjoy flying the Dolphin 40 ARF as much as we have enjoyed designing it for you. We
encourage you to let us know about your successes. Again, thank you for purchasing the Dolphin 40 ARF
by Phoenix Model.
ADDITIONAL ITEMS REQUIRED
о40-53 Two Stroke Engine
о4 Channel Radio With 4 Servos
оGlow Plug to Suit Engine
оPropeller to suit Engine
оGP foam rubber.
оSilicon Fuel Line
оGP stick on lead weight.
TOOLS AND SUPPLIES NEEDED
оGP thick CA.
оGP Pro 30 - Minute epoxy
оGP Pro 6 - Minute epoxy.
оHand or Electric Drill
оAssorted Drill Bits
оModeling Knife
оStraight Edge Ruler
о2mm Bondhus Ball Driver # 10654
1
Instruction Manual Dolphin 40
**SUGGESTION** to avoid scratching your new airplane, do not unwrap the pieces until they are
needed for assembly. Cover your workbench with an old towel or brown paper, both to protect the
aircraft and to protect the table. Keep a couple of jars or bowls handy to hold the small parts after
you open the bags.
**NOTE** Please trial fit all the parts. Make sure you have the correct parts and that they fit and are
aligned properly before gluing! This will assure proper assembly. Since the Dolphin 40 ARF is hand
made from natural materials, every plane is unique and minor adjustments may have to be made.
However, you should find the fit superior and assembly simple.
Wing Assembly
*Note* We highly recommend using 30 Minute
Epoxy over faster curing epoxies for several
reasons. First, slower curing epoxy is stronger. It
also providers more working time, allowing the
builder to properly align the parts. Using fast
cure epoxy when joining the wing halves could
result in the glue drying before the wing halves
are aligned properly, causing damage to the
wing assembly. Also, when joining the wing
halves, the entire area of both center ribs need
to be joined completely with no gaps existing.
Not following these steps carefully, may result in
failure of the wing center section during flight.
1. Locate the plywood wing dihedral brace.
Using a ruler, locate it's center and place a
mark. Draw a vertical line at the mark just
made.
2. Test fit the dihedral brace into each wing
half. The brace should slide in easily up to
the centerline you drew. If it does not, use
220 grit sandpaper with a sanding block and
sand down the edges and ends of the brace
until the proper fit is obtained.
*Note* the dihedral brace is cut in the shape
of a "V". This shape gives the wing the
correct dihedral angle. Make sure you don't
test fit the brace upside down.
3. When satisfied with the fit of the dihedral
brace in each wing half, remove the brace
.Mix equal amounts of part A and part B 30
minute epoxy. Coat all sides of the dihedral
brace box and half of the wing brace with the
epoxy. Make sure to cover the top and
bottom as well as the sides. Use enough
epoxy to fill any gaps.
4. Insert the dihedral brace into one wing half
up to the centerline. Wipe off any excess
epoxy that may have squeezed out of the
joint using paper towels.
make centerline
2
Dihedral brace
1
3
Instruction Manual Dolphin 40
Control Throws
** Note** Both the center of gravity and the
control throws are a good starting place for initial
test flying and may be changed to your
particular tastes and flying styles once you have
become familiar with the Dolphin 40. We do
recommend initially flying the airplane using the
LOW RATE settings. Too much throw can force
the plane into a high speed stall, so remember,
"More it not better".
Flight preparation
1) Check the operation and direction of the
elevator, rudder, ailerons and throttle.
A) Plug in your radio system per the
manufacturer's instructions and turn
everything on.
B) Check the elevator first. Pull back on the
elevator stick. The elevator should go up. If
it does not, flip the servo revesing switch
on your transmitter to change the direction.
C) Check the rudder. Looking from behind the
airplane, move the rudder stick to the right.
The rudder should move to the right. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
D) Check the throttle. Moving the throttle stick
forward should open the carburetor barrel.
If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
E) From behind the airplane, look at the
aileron on the right wing. Move the aileron
stick to the right. The aileron should move
up and the other aileron should move
down. If it does not, flip the servo reversing
switch on your transmitter to change the
direction.
Receiver & Battery Installation
1. The battery should be wrapped in foam and
mounted behind the fuel tank. As the picture
22.
2. The receiver should be wrapped in foam and
mounted just behind the battery. As the
picture 22.
3. Uncoil the receiver antenna completely and
drill a 1/16'' hole in the side of the fuselage,
opposite the muffler, for the antenna to exit.
Secure the end of the antenna to the top the
vertical fin using a rubber band or similar
method.
4. Install the switch on the side of the fuselage
opposite the muffler. Use the faceplate of the
switch as a pattern for drilling the holes and
the cutout for the switch itself.
Balancing
1. It is critical that your airplane be balanced
correctly. Improper balance will cause your
plane to lose control and crash. The center of
gravity is located 3-1/2'' back from the
leading edge of the wing at the fuselage
sides. This location is recommended for
initial test flying and trimming. There is a 3/8''
margin forward and aft, but it is not
recommended that the center of gravity be
located any further back than 3-7/8''. Balance
the Dolphin 40 with the fuel tank empty.
2. Using a couple of pieces of masking tape or
a pen, make a mark on each side of the top
of the wing 3-1/2'' back from the leading
edge.
3. Turn the Dolphin 40 upside down and place
your fingers on the marks on top of the wing
and carefully lift the plane.
4. If the nose of the plane falls, the plane is
nose heavy. To correct this, try moving your
battery pack back. It that is not enough
change, add a little lead weight to the tail. If
the tail of the plane falls, double check that
you have mounted the battery pack under
the fuel tank. If the airplane is still tail heavy
add lead weight to the firewall or even better,
use a sufficient heavy hub under the spinner.
High rate Low rate
Ailerons: 1/2'' up & down 3/8'' up & down
Elevator: 5/8''up & down 3/8'' up & down
Rudde: 1'' right & left 1/2''right & left
12
Instruction Manual Dolphin 40
Flying the DOLPHIN 40
If you are unfamiliar with flying low wing sport
aircraft, please seek out an experienced pilot to
help you with the first few flights of the airplane.
The design of the Dolphin 40 allows the
airplane to fly smoothly and stable, yet perform
good aerobatics as well. Landings are smooth
and predictable, but because this is not a
primary trainer, its stall speed is higher and
power should be used to bring it in for landings
and slow speed flight. It does not have the
self-recovery characteristics of a primary R/C
trainer, so again, if you don't feel comfortable for
the first flight have someone with more
experience help you get it in the air.
Although this model has good low speed
characteristics with power on, you should
always build up as much speed as your runway
will permit before lifting off, as this will give you
a safety margin in case the engine quits after
take off.
It is important that the plane rolls out on the
ground until sufficient airspeed is achieved.
Pulling the Dolphin 40 off the ground too soon
could result in a stall and crash. Allow the
airplane to pick up speed and gently lift off and
climb out gradually. We recommend that you
take it easy with your Dolphin 40 for the first
several flights, gradually getting acquainted with
the air plane and allowing your engine to fully
break-in. Add and practice one maneuver at a
time, learning how the airplane be haves in
each. For smooth flying and normal maneuvers,
we recommend using the low rate settings
described earlier, Hight rate may be required for
more crisp aerobatics.Before your first landing,
practice landing approaches in the air. This will
get you familiar with the stall characteristics of
the Dolphin 40.
When it's time to land, fly a normal landing
pattern and approach decreasing power to about
one-quarter. It is important that when power is
reduced and flying speed has diminished, do not
make high angle turns onto the final approach.
Too hight an angle of bank with too litter power
can cause the airplane to stall. When you turn
final, reduce power to just a few clicks over idle.
When you are a few feet off the ground, reduce
power to idle and let the airplane settle onto the
runway. Land slightly faster than the stall speed
and on the main wheels, as this is the easiest
way to land the Dolphin 40 and will reduce the
risk of stalling the airplane.
2) Check Control Surface Throw.
A) The rudder should move 1/2'' left and 1/2''
right from center.
B) The elevator should move 3/8'' up and 3/8''
down from center.
C) The aileron should move 3/8'' up and 3/8''
down from center. If they move too far,
move the adjustable horn away from the
aileron a few turns. Do the opposite if there
is not enough throw. It is important that
both ailerons move the same amount, both
up and down.
D) Once the control throws and movements
are set, tubing must be added to the
clevises to ensure they do not release in
the air. Cut 1/4'' lengths of fuel tubing and
slide one over each clevis prior to
attaching it to the control horn. This will
ensure the clevis will not release in flight.
Pre-Flight Check
1) Completely charge your transmitter and
receiver batteries before your first day of flying.
2) Check every bolt and every glue join in your
Dolphin to ensure everything is tight and well
bonded.
3) Check that the tubes used for clevis retainers
are in place.
4) Double check the balance of the airplane. Do
this before filling the tank with fuel.
5) Check the control surfaces. All should move
in the correct direction and not bind in any way.
6) Check the receiver antenna. It should be fully
extended and not still coiled up in the fuselage.
13
Instruction Manual Dolphin 40
8
7
Wing Installation
1. Locate the two predrilled holes in the wing
that accept the two nylon wing bolts. Using a
modeling knife, remove the covering from
over them. This needs to be done on both the
top and the bottom of the wing.
2. Place the wing into the wing saddle. Check
the alignment of the predrilled holes in the
fuselage bulkhead with the wing dowels
installed in the font of the wing. The holes in
the fuselage may need to be adjusted slightly
to line up perfectly with the dowels. If you
need to adjust the holes, a small round file
works best for this.
3. Test fit the two nylon wing bolts through the
predrilled holes in the wing and into the
threaded insert in the wing mounting blocks
in the fuselage. You may need to adjust the
perdrilled holes in the wing to align perfectly
with those in the fuselage. If so, use a
modeling knife or drill to slightly elongate the
holes in the wing until they are aligned with
those in the fuselage.
4. When satisfied with the alignment of the
holes in the wing, remove the wing and drill
out the holes using a 5/16'' drill bit. These
larger holes will accept the nylon bushings.
5. Place the wing back in the wing saddle and
test the fit of the nylon screws and bushings.
Also, the hole in each control horn may need to
be enlarged slightly to allow the nylon clevis pin
to be installed without binding.
5. 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.
6. Center the aileron and hold it in place using a
couple of pieces of masking tape.
7. 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.
8. Using pliers, carefully make a 90 degree bend
down at the mark made. Cut off the excess
wire, leaving about 4mm beyond the bend.
9. 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.
10. Repeat these step to install the second
aileron linkage.
Remove the covering
Wing hold down screw
Nylon bushing
6
Metal pushrod
Nylon clevises
Nylon snap keeper
Screw
5
Instruction Manual Dolphin 40
9
2. Bolt the wing to the fuselage. Set the
horizontal stabilizer onto the stabilizer
mounting platform on the fuselage. To align
the horizontal stabilizer with the wing, use
figure #2 and # 3. when viewed from the rear,
the horizontal stabilizer should be level with
the wing. If it is not level, use sandpaper and
sand down the high side of the stabilizer
mounting platform until the proper alignment
is achieved. Measure the distance form each
wing tip to each stabilizer tip. These distances
should be equal. If they are not, adjust the
stabilizer until the measurements are equal.
3. When you are satisfied with the alignment,
hold the stabilizer in place with T-pins or
masking tape, but do not glue at this time.
4. On the bottom of the horizontal stabilizer,
draw a line where it and the fuselage meet.
Do this on both the right and left sides.
5. Remove the horizontal stabilizer. Using the
lines you just drew as a guide, carefully
remove the covering from between them,
using a modeling knife. This is where the
horizontal stabilizer will be glued in place.
6. When you are sure that every thing is aligned
correctly, glue the horizontal stabilizer in
place using 30Minute Epoxy. Double check
all of your measurements once more before
the epoxy cures. Hold the stabilizer in place
with T-pins or masking tape until the epoxy
has cured.
7. Slide the vertical stabilizer into the slot in the
mounting platform in the top of the fuselage.
Mark the shape of the fuselage on the left
and right sides of the vertical stabilizer using
a felt-tip pen.
8. Now, remove the vertical stabilizer and using
a modeling knife, carefully cut just inside the
marked lines and remove the film on both
sides of the vertical stabilizer. Just as you did
with the horizontal stabilizer, make sure you
only press hard enough to cut the film, not the
balsa vertical stabilizer.
6. With the bushings in place, thread the screws
into the nylon inserts in the wing mounting
block in the fuselage, but do not tighten the
screws completely. When satisfied with the fit
of the bushings, apply a small amount of 6
Minute Epoxy to glue the bushings in place.
Be careful to not get any glue on the bolts.
7. Once the epoxy has set, remove the screws
and apply any additional epoxy needed to
completely secure the bushings into the wing.
Horizontal and vertical
stabilizer installation
1. Using your ruler, find the centerline of the
horizontal stabilizer, at the trailing edge, and
place a mark. Use a triangle and extend this
mark, from back to front, across the top and
bottom of the stabilizer. Also place a mark at
the centerline of the fuselage at the front and
rear of the stabilizer mounting area. These
mark will be used to line up the stabilizer to
the fuselage.
FIGURE # 3
FIGURE # 2
AA-1
A=A-1
A=A-1
ABB1 A1
90
O
B=B-1
Glue with epoxy
6
Instruction Manual Dolphin 40
Spinner installation
1. Locate the molded plastic spinner, two
3*12mm Phillips head sheet metal screws
and the Propeller to suit your engine (not
included).
9
Instruction Manual Dolphin 40
5. Push the stopper assembly into the opening
in the tank. Adjust the assembly until the
muffler pressure tube is resting in the top of
the bubble in the tank, but not touching the
bubble. The fuel pick-up should also be 3/8''
from the back of the tank. When satisfied
with the fit, insert the long machine screw
through the center hole in the stopper.
Tighten the screw to expand the stopper and
seal the tank opening. Tighten the stopper
only enough to make a good seal. If you
over-tighten the stopper, you may
accidentally crack the front of the tank.
6. Mix up a batch of 30 Minute Epoxy and using
an small pain brush, completely coat the
inside of the fuel tank compartment in the
forward section of the fuselage. This will seal
the wood from any fuel that might
accidentally leak from the tank.
7. When the epoxy has cured, connect two
lengths of fuel line to the plastic tubes
coming out of the tank. Keep track which one
is for the fuel pick-up and which one is for the
muffler pressure.
8. Run the tubes through the hole in the firewall
and slide the tank assembly into place. The
tank should rest at the top of the
compartment and be up against the back of
the firewall. Make sure there are no kinks in
the fuel tubing and that the bubble in the tank
is towards the top of the airplane.
9. Use pieces of the foam provided to hold the
tank in place. Be careful the tank or the foam
doesn't interfere with the pushrods.
10. Connect the fuel pick-up line to the
carburetor fuel inlet nipple and the muffler
pressure line to the pressure nipple on your
engine's muffler.
2. Most .40 size displacement engines use a 1/4''
diameter crankshaft. You may need to enlarge the
hole in the spinner backplate and the propeller to
fit the crankshaft. If you do, enlarge the holes
using a prop reamer or a 1/4'' size drill bit.
3. Slide the backplate, then the propeller onto the
engine and secure in place with the prop
washer and nut included with your engine.
4. Install the spinner cone onto the spinner
backlate using the two 3*12mm Phillips head
sheet metal screws. You will need to trim the
openings in the spinner cone to clear the
propeller. Trim the opening using a sharp
modeling knife until the spinner cone clears the
propeller. It is important that no part of the
spinner cone touches the propeller.
INSTALLING THE ELEVATOR PUSHROD
1. Carefully cut away the covering material from
the slot.
2. Working from inside the fuselage, slide the
threaded end of the pushrod until it reaches the
exit slot. Carefully reach in with a small screw
driver and guide the pushrod out of the exit slot.
SERVO INSTALLATION
INSTALLING THE FUSELAGE SERVOS
1. Install the rubber grommets and brass collets
into the elevator, rudder and throttle servos.
Test fit the servos into the servo tray. Trim the
tray if necessary to fit your servos
2. Mount the servos to the tray using the mounting
screws provided with your radio system.
17
10
Instruction Manual Dolphin 40
INSTALLING THE RUDDER PUSHROD
1. Locate the pushrod exit slot on the left of the
fuselage.
2. Carefully cut away the covering material from
the slot.
3. Working from inside the fuselage, slide the
threaded end of the remaining pushrod down
the inside of the fuselage until the pushrod
reaches the exit slot. Carefully reach in with a
small screw driver and guide the pushrod out
of the exit slot.
4. Install the clevis on the rudder pushrod. Make
sure 6mm of thread shows inside the clevis.
5. The control horn should be mounted on the
right side of the rudder at the leading edge, in
line with the rudder pushrod.
6. Drill two 1,6mm holes through the rudder using
the control horn as a guide and screw the
control horn in place.
7. Attach clevis to the third hole in the control
horn. Install a silicone tube on the clevis.
8. 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 to accommodate the rudder pushrod
wire.
9. Plug the rudder servo into the receiver and
center the servo. Install the servo arm onto the
servo.
10. Center the rudder and hold it in place using a
piece of masking tape.
11. With the rudder and rudder servo centered,
carefully place a mark on the rudder pushrod
wire where it crosses the hole in the servo arm.
Control horn
3. Install the clevis on the elevator pushrod. Make
sure 6mm of thread shows inside the clevis.
4. The control horn should be mounted on the
bottom, left side of the elevator at the leading
edge, in line with the elevator pushrod.
5. Drill two 1,6mm holes through the elevator
using the control horn as a guide and screw the
control horn in place.
6. Attach clevis to the third hole in the control horn.
Install a silicone tube on the clevis.
7. 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 to accommodate the elevator
pushrod wire.
8. Plug the elevator 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
fuselage.
9. Be sure both elevator halves are flat . Slightly
adjust the wire joiner if necessary. Center both
elevator halves and hold them in place using a
couple of pieces of masking tape.
10. With the elevator halves and elevator servo
centered, carefully place a mark on the elevator
pushrod wire where it crosses the hole in the
servo arm.
11. Using pliers, carefully make a 90 degree bend
up at the mark made. Cut off the excess wire,
leaving about 8mm beyond the bend.
12. Insert the 90 degree bend up 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 the elevator halves.
18
Clevis
19
KIT CONTENTS: We have organized the parts as they come out of the box for better identification during
assembly. We recommend that you regroup the parts in the same manner. This will ensure you have all of parts
required before you begin assembly.
AIR FRAME ASSEMBLIES
• (2) Wing halves with ailerons
• (1) Fuselage with canopy.
• (1) Horizontal stabilizer with elevator halves
• (1) Vertical stabilizer with rudder
• (1) Instruction manual
MAIN GEAR ASSEMBLY
• (2) Main gear
• (2) 60mm diameter wheels
• (4) Wheel collars
• (4) 3mm x 4mm set screws
• (2) Nylon plate
• (4) 3mm x 12mm screws
TAIL GEAR ASSEMBLY
• (1) Tail gear
• (1) 25mm diameter wheel
• (1) Wheel collar
• (1) 3mm x 4mm set screw
• (2) Nylon clasps
• (6) 2mm x 10mm set screw
ELEVATOR CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
RUDDER CONTROL SYSTEM
• (1) Nylon clevises
• (1) Silicon tube
• (1) Nylon snap keeper
• (2) 2mm x 16mm screws
• (1) Nylon control horn w/plate
AILERON CONTROL SYSTEM
• (2) Metal pushrod
• (2) Nylon clevises
• (2) Silicon tube
• (2) Nylon snap keeper
• (2) Nylon control horn
MOTOR MOUNT ASSEMBLY
• (4) 3mm x 20mm machine screws
• (4) Lock washer
THROTTLE CONTROL SYSTEM
• (1) 1,3mm x 500mm wire
• (1) 3,5mm x 350mm nylon pushrod housing
• (1) Metal connector
• (1) 4mm x 4mm machine screw
FUEL TANK
• (1) Nylon fuel Tank
• (1) Metal clunk
• (1) Silicone tube / 110mm
• (1) Pre - assembled stopper w / 2 tube
• (1) 165mm x 250mm foam padding
MISCELLANEOUS ITEMS
• (1) Wood dihedral
• (1) 25mm x 600mm trim tape
• (4) 6mm x 45mm nylon screws
• (2) Plate of nylon screw
• (1) Spinner
• (2) Accessary Bag of wood
• (1) Decal sheet
• (1) Set of pushrod
ADDITIONAL ITEMS REQUIRED
• 40 two stroke Engine.
• 4 channel Radio with 4 servos.
• Glow plug to suit Engine.
• Propeller to suit Engine.
• Protective foam Rubber.
• Silicone fuel line.
• Stick on weight for balance.
KIT CONTENTS
2
Instruction Manual Dolphin 40
3
4
5. Once the epoxy has cured, trial fit both wing
halves together.The center gribs should fit
flush together with little or no gaps existing. If
gaps do exist, use 220 Grit sandpaper and
sand down the high spots on the root ribs and
the wing joiner until the proper fit is obtainer.
The amount of dihedral is built into the wings
by angling the root ribs the correct amount.
With one wing half flat on the table, the other
wing tip should be approximately 2" off of the
surface of the table. If this need to be
adjusted, you may do so by sanding small
amount from the center ribs or dihedral brace.
6. To protect the covering from the epoxy used to
glue the wing halves together, carefully apply
masking tape around the edge of the root rip
on the top and bottom of each wing half.
7. Mix a generous amount of 30 minute epoxy.
Coat the exposed half of the dihedral brace,
the wing joiner box and both root ribs with
epoxy. Slide the two wing halves together
and carefully align them at the leading and
trailing edges. Wipe away any excess epoxy
using paper towels. Use masking tape
wrapped around the center section to hold
the halves in place until the epoxy cures.
8. When the epoxy has cured, carefully remove
the masking tape from the wing.
9. Peel off the backing from the self adhesive
covering strip used to cover the center
section wing joint seam. Apply the strip to the
center section of the wing on the bottom first,
and the top using the rest of the material.
Aileron Servo Installation
1. Test fit the aileron servo into the ply-wood
servo tray. The servo should be mounted with
the output shaft towards the leading edge of
the wing and the servo wire should run out the
top of the wing through a notch cut in the side
of the servo tray. Depending on the size of the
servo you chose, you may need to trim the
in-side edges of the servo tray using a
modeling knife to allow the servo to fit
properly.
2. When satisfied with the fit, mount the servo
using the hardware provided by the radio
manufacturer. Drill 1/16'' pilot holes through
the servo tray at the mounting screw locations
before in-stalling the screws. This will prevent
the plywood from splitting.
3. Locate two nylon clevises and the two 140mm
threaded rods. Carefully thread the clevises
onto the rods. To prevent the clevises from
coming off the rods in flight, make sure you
thread them on completely.
4. Connect the two clevises to the installed
adjustable aileron control horns. The two
control horns should be adjusted so they are
even with the top of the torque rod.
Apply masking tape around
edge of join on each winghafl
5
Aileron servo
Servo tray
Control horn
4
Instruction Manual Dolphin 40
14
Fuel Tank Assembly
1. Locate the plastic molded fuel tank,
preassembled stopper assembly, weighted
pick-up and a length of fuel line about 2-1/2 ''
long (not included). For steps # 2-4, refer to
photo #16 below.
3. Test fit the two main gear wires into the
channel. When satisfied with the fit, secure
the wires in place using the two nylon straps
and four 3*12mm sheet metal screws. If you
look closely at the surface surrounding the
channel for the wire, you will notice that there
are already four pilot holes drilled to
accommodate the screws for the straps.
Mount the straps at these locations.
4. Install two of the wheels onto the axles using
the four wheel collars and set screws
provided. The wheels should be centered on
the axles with a wheel collar on each side,
holding them in place. Tighten the set screws
on the collars to secure them in place.The
wheels should rotate freely. You should apply
a small drop of lock-Tite thread lock to each
set screw to prevent them from coming loose.
5. Set the tail wheel assembly in place on the
plywood plate.
6. Drill 2,6mm pilot holes through the plywood
plate.
7. Secure the tail wheel bracket in place using
two 3mm x 12mm screw.
8. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder. The
control clasp has a pre-drilled hole through
the top of it. Slide this hole on to the tail wheel
wire while sliding the clasp over the bottom of
the rudder.
9. Secure the two clasps to the rudder bottom
using two 2mm x 10mm screws.
Main gear
Wheel
Wheel Screw
Nylon plate
Vent tube
Stopper assembly Fuel line
Clunk
Fuel pick-up tube
16
8
Instruction Manual Dolphin 40
2. Attach the weighted pick-up, more
com-momly referred to as the "clunk", to one
end of the silicon fuel line.
3. Slide the other end of the silicon fuel line
onto the end of one of the tubes coming out
of the rear of the stopper assembly. This will
be your fuel pickup line. When mounted the
clunk should rest 3/8'' from the rear of the
tank and should move freely within the tank.
The silicon tubing should be trimmed to fit.
4. Using your Fingers, gently bend the second
tube upwards. This will become the muffler
pressure tube. When inside the tank, it
should rest just within the bubble in the top of
the tank's roof.
Screw
Screw
clasps
15
10 11
12
5. Mount the muffler to the engine using the
mounting bolts provided with your engine.
Landing Gear Installation
1. Locate the two main landing gear wires, one
tail gear wire, two nylon mounting straps,
four 3*12mm Phillips head sheet metal
screws, three wheels, six wheel collars
w/set screws.
2. There are one hardwood landing gear blocks
with one precut channel in the bottom of the
fuselage. Using a modeling knife, remove the
covering from over the precut channels.
9. Set the vertical stabilizer back in place. Using
a triangle, check to ensure that it is 900to the
horizontal stabilizer.
10. Once you are sure that everything is aligned
correctly, glue the vertical stabilizer in place
using 30 Minute Epoxy. Double check all of
your measurements once more before the
epoxy cures. Hold the stabilizer in place with
T-pins until the epoxy has cured.
Engine Mounting
1. Test fit your engine into the engine mount.
Because the width of different engines differ,
the motor mount may need to be widened to
accommodate your engine.
2. Remove the muffler from the engine and set
the engine in the mount. Adjust the depth of
the engine in the mount. The front of the
thrust washer should be 3/4'' forward of the
front edge of the fuselage sides. This will
allow clearance for the propeller.
3. Once satisfied with the fit of the engine, mark
the position of the four engine mounting holes
onto the mount. Remove the engine and drill
out the mounting holes using a 7/64'' drill bit.
Drill one hole at a time, checking the
alignment after each hole is drilled.
4. When reinstalling the engine into the motor
mount, connect the carburetor arm to the
preinstalled throttle pushrod. The Z-Bend fits
into the lower hole in the throttle arm. Mount
the engine using the four3*25mm flat head
wood screws.
Glue with epoxy
Remove the covering
13
7
Instruction Manual Dolphin 40
3/4"
11
Instruction Manual Dolphin 40
12. Using a pliers, carefully make a 90 degree
bend up at the mark made. Cut off excess
wire, leaving about 8mm beyond the bend.
13. Insert the 90 degree bend up 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 rudder.
INSTALLING THE THROTTLE
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 connector
apply a small drop of thin C/A to the bottom nut.
This will prevent the connector from loosening
during flight.
2. Plug the throttle servo into the receiver and turn
on the radio system. Check to ensure that the
throttle servo output shaft is moving in the
correct direction. When the throttle stick 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.
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. Manually 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 carburator 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.
6. Glue the 1/2'' *1/2''*1/4'' pieces of wood between
the fuselage side and the steering pushrod
housing to help hold the housing in place and
prevent it from flexing. Use the same technique
as with the throttle.
!!!
Control horn
20
Elevator Servo
Rudder
Motor control servo
Switch
22
Clevis
21
Receiver Battery I/C FLIGHT GUIDELINES
Made in Vietnam
When ready to fly, first extend the
transmitter aerial.
Operate the control sticks on the
transmitter and check that the control
surfaces move freely and in the
CORRECT directions. ALWAYS land the model INTO the
wind, this ensures that the model lands
at the slowest possible speed.
Switch on the transmitter.
Switch off the transmitter.
Check that the transmitter batteries
have adequate power.
Switch off the receiver.
Switch on the receiver. ALWAYS take off into the wind.
Check that the wings are correctly
fitted to the fuselage. If the model does not respond correctly
to the controls, land it as soon as
possible and correct the fault.
Empty the fuel tank after flying, fuel left
in the tank can cause corrosion and
lead to engine problems.
I/C FLIGHT WARNINGS
14
Instruction Manual Dolphin 40
Always operate in open areas, away
from factories, hospitals, schools,
buildings and houses etc. NEVER fly
your aircraft close to people or built
up areas.
THE PROPELLER IS DANGEROUS
Keep fingers, clothing (ties, shirt
sleeves, scarves) or any other loose
objects that could be caught or drawn
in, away from the propeller. Take care
at ALL times.
Keep all onlookers (especially small
children and animals) well back from
the area of operation. This is a flying
aircraft, which will cause serious
injury in case of impact with a person
or animal.
NEVER fly near power lines, aerials
or other dangerous areas including
airports, motorways etc.
NEVER use damaged or deformed
propellers or spinners.
DO NOT dispose of empty fuel
containers on a fire, this can lead to
an explosion.
NEVER fly in wet conditions or on
windy or stormy days.
ALWAYS adjust the engine from
behind the propeller, and do not allow
any part of your body to be in line
with the propeller.
We wish you many enjoyable flights with your plane and one again thank you for your choosing a Phoenix Model products.
Wing span : 1556mm [61.25 in]
Length : 1296mm [51 in]
Wing Area : 40.5dm2 [628sp.in]
RTF Weight : 2381g [84oz] 5.25 lbs
Wing Loading : 73g/dm2 [24 oz / ft2]
Engine : 40 - 46 two stroke
Radio require : 4 channel
Instruction Manual