Seagull Models ZERO FIGHTER User manual

Hand-made Almost Ready to Fly R/C Model Aircraft
ASSEMBLY MANUAL
Made in Vietnam
Specifications
Wingspan ----------------------- .148 cm--------------- 58.3 in.
Wing area ----------------------- 3474sq. cm ---- 538.4sq in.
Approximate flying weight ----- 2.8 - 3.0kg ----6.2 - 6.6 lb.
Recommended engine size ---------- 0.40 - .48 2 stroke.
0.50 - .72 4 stroke.
Recommended R/C ------------- 4 channel with 5 servos.
Flying skill level ------------------- Advanced / Intermediate.
Kit features
• Ready-made—minimal assembly & finishing required
• Ready-covered covering
• Factory-installed pushrods
• Factory-installed engine mount
• Factory-pinned & glued control surface hinges for ultimate safety
• Comprehensivehardwarepackincludingwheels,tank,spats,undercarriage& spinner
• Photo-illustrated step-by-step Assembly Manual
Additional items required
Engine
4 Channel or greater Radio Control system
Glues
Tools
Starting Equipment

ZERO FIGHTER. Instruction Manual
2
INTRODUCTION
Thank you for choosing the Zero fighter ARTF by SEAGULL MODELS. The Zero fighter was
designed with the intermediate/advanced sport flyer in mind. It is a semi scale airplane which is
easy to fly and quick to assemble. The airframe is conventionally built using balsa, plywood and
veneer to make it stronger than the average ARTF , yet the design allows the aeroplane to be kept
light.Youwillfindthatmostoftheworkhasbeendoneforyoualready.Thepushrodsarepre-made
to the correct lengths, the motor mount has been fitted and the hinges are pre-installed and pinned
for security. Flying the Zero fighter is simply a joy.
This instruction manual is designed to help you build a great flying aeroplane. Please read this
manual thoroughly before starting assembly of your Zero fighter . Use the parts listing below to
identify all parts.
WARNING
Please be aware that this aeroplane is not a toy and if assembled or used incorrectly it is
capable of causing injury to people or property. WHEN YOU FLY THIS AEROPLANE YOU
ASSUME ALL RISK & RESPONSIBILITY.
IfyouareinexperiencedwithbasicR/CflightwestronglyrecommendyoucontactyourR/Csupplier
and join your local R/C Model Flying Club. R/C Model Flying Clubs offer a variety of training
proceduresdesignedtohelpthenewpiloton his waytosuccessfulR/Cflight.Theywillalsobeable
to advise on any insurance and safety regulations that may apply.
ADDITIONAL ITEMS REQUIRED
!.40-.48 2-stroke engine.
.50-.72 4-stroke engine.
!4-channel radio with five servos.
!Glow plug to suit engine.
!Propeller to suit engine.
!Protective foam rubber for radio
system.
!Silicone fuel line.
!Stick-on weights for balance
(If necessary).
TOOLS & SUPPLIES NEEDED
!Thick cyanoacrylate glue.
!30 minute epoxy.
!5 minute epoxy.
!Hand or electric drill.
!Assorted drill bits.
!Modelling knife.
!Straight edge ruler.
!2mm ball driver.
!Phillips head screwdriver.
!220 grit sandpaper.
!90° square or builder’s triangle.
!Wire cutters.
!Masking tape & T-pins.
!Thread-lock.
!Paper towels.
PARTS LISTING
FUSELAGE ASSEMBLY
!(1) Fuselage
WING ASSEMBLY
!(1) Right wing half with pre-installed
aileron.
!(1) Left wing half with pre-installed
aileron.
!(1) Plywood wing dihedral brace.
!(1) Covering strip for centre section
joint.
Tail section assembly
!(1) Vertical stabilizer with pre-
installed rudder
!(1) Horizontal stabilizer with pre-
installed elevator halves.
Some more parts.
HARDWARE PACK
COWLING

ZERO FIGHTER. INSTRUCTION MANUAL
3
NOTE:To avoid scratching your new aero-
planewesuggestthatyoucoveryour
workbench with an old towel. Keep a
couple of jars or bowls handy to hold
the small parts after you open the
bags.
Pleasetrialfitallparts.Makesureyou
havethecorrectpartsandthattheyfit
andarealignedproperlybeforegluing!
This will ensure proper assembly as
the Zero fighter is made from natu-
ral materials and minor adjustments
may have to be made.
The paint and plastic parts used in
this kit are fuel proof. However, they
arenottolerantofmanyharshchemi-
cals including the following: paint
thinner, cyano-acrylate glue accel-
erator,cyanoacrylategluede-bonder
andacetone.Donotletthesechemi-
calscome in contactwith the colours
onthecoveringandtheplasticparts.

ZERO FIGHTER. Instruction Manual
4
!6) Reinstall the gear wire and install the
straps using the four 3mm x 12mm wood
screws. Tighten the screws completely to
secure the gear wire in place.
PARTS REQUIRED
LANDING GEAR INSTALLATION
!{2} Prebent Main Gear Wires
!{2} 60mm Diameter Wheels
!{4} Nylon Landing Gear Straps
!{8} 3mm x 12mm Wood Screws
!{4} Wheel Collars w/3mm x 6mm Set
Screws
INSTALLING THE MAIN GREAR WIRES
!1) Using a modeling knife, remove the
covering from over the two main gear mount-
ing slots located in the bottom of the wing.
!2) Insert the 90º bend of one main gear
wire into the predrilled hole in one mounting
slot.
!3) The landing gear wire is held in place
using two nylon landing gear straps and four
3mm x 12mm wood screws.
The straps should be located equal distance
from the inside and outside ends of the wire.
!4) Using the two landing gear straps as
a guide, mark the locations of the four 3mm x
12mmmountingscrewsontothewingsurface.
!5) Remove the two straps and the gear
wire. Drillfour 1.5mm pilotholesinto the wing
for the wood screws. Be careful not to drill
through the top of the wing!
!7) Slide one wheel collar with 3mm x
6mm set screw onto each axle. Push the
wheel collars on as far as they will go and
tighten the set screws.
Be careful not to overtighten the set
screws. Overtightening may cause the
threads to strip.
!8) Slide one 60mm diameter wheel onto
eachaxleandpushthemupagainstthewheel
collars. Slidetheremaining wheel collars with
3mm x 6mm set screws onto the axles. Push
them up against the wheels and tighten the
set screws. The wheels should spin free and
not bind in any way. If they do bind, loosen
the set screws in the outer wheel collars and
move the collars out a small amount. Re-
tighten the set screws.
Nylon landing gear strap

ZERO FIGHTER. INSTRUCTION MANUAL
5
!1) Use a small weight(Weighted fuel pick-
up )+thread to feed the servo connector
through the wing as indicated
INSTALLING THE AILERON SERVOS.
string
small weight
! 2) Attach the string to one end of servo
lead and carefully thread it though the wing.
Once you have thread the lead throught the
wing, remove the string so it can use for the
other servo lead.

ZERO FIGHTER. Instruction Manual
6
Because the size of servos differ, you
may need to adjust the size of the
precut opening in the mount. The notch
in the sides of the mount allow the servo
lead to pass through.
!4) Install the aileron servo into the servo
mount, withthe outputshaft towards thetrail-
ing edge of the wing, using the wood screws
provided with your radio system. Drill 1mm
pilot holes through the mount
Repeat the procedure for the other wing
half.
PARTSREQUIRED
!{2} 2mm x 180mm Threaded Wires
!{2} Nylon Adjustable Control Horns
!{2} Nylon Clevises
!{4} Machine screws 2MM x 20MM
!{2} Set control horns.
!3) Install the rubber grommets and brass
colletsontotheaileronservo. Testfittheservo
into the aileron servo mount.
INSTALLING THE AILERON LINKAGE
!1) Using a ruler & pen to draw a straight
line as below picture.
2) Locate the two nylon control horns, two
nylon control horn backplates and four
machine screws.
!!
!!
!3) Position the aileron horn on the bottom
side of aileron. The clevis attachment holes
should be positioned over the hinge line.
ControlHorn
MountingScrews MountingPlate

ZERO FIGHTER. INSTRUCTION MANUAL
7
!!
!!
!4)Usinga1mmdrillbitandthecontrol horns
as a guide, drill the mounting holes through
the aileron halves.
6) Thread one nylon adjustable control
horn onto each aileron torque rod. Thread
the horns on until they are flush with the ends
of the torque rods.
!!
!!
!5)Mount the control horns by inserting the
screws through the control horn bases and
aileron halves, then into the mounting
backplates. Do Not overtighten the screws or
the backplates may crush the wood.
7) Connect the clevis to the control horn
and lay the wire across the servo arm. Mark
the wire where it crosses over the arm holes.
8) Cut the wire 1/2” past the mark and
make an “ L ” bend .
9) Connect the control wire to the servo
and aileron horn as shown. Use the “ L” bend
keeperto secure the control wiretothe servo
arm.
10mm

ZERO FIGHTER. Instruction Manual
8
! 2. Test fit the dihedral brace into each
wing half. The brace should slide in
easily up to the centreline that you
drew. If not, use 220 grit sandpaper
with a sanding block and sand down
theedgesandendsofthebraceuntil
it fits properly.
! 3. Remove the brace when satisfied
withitsfitineachwinghalf.Coatboth
sidesofonehalfofthedihedralbrace
with 30 minute epoxy. Next, pour
some epoxy into the dihedral box in
onewingpanel.Makesureyoucover
the top and bottom as well as the
sides of the dihedral brace. Use
enough epoxy to fill any gaps.
! 4. Insert the dihedral brace into the di-
hedral box up to the centreline. With
paper towels wipe off any excess
epoxythatmayhavesqueezedoutof
the joint .
Carefully slide the two wing halves together
and firmly press them together, allowing the
excess epoxy to run out. there should should
notbeanygapinthewinghalves.Userubbing
alcohol and a paper tower to clean up any
excess epoxy.
Applymaskingtapeat the wing join toholdthe
wing halves together securely.
WING ASSEMBLY
NOTE:We highly recommend using 30
minute epoxy as it is stronger and
providesmoreworkingtime,allowing
thebuildertoproperlyaligntheparts.
Using fast cure epoxy when joining
the wing halves could result in the
glue drying before the wing halves
arealignedproperlywhichmayresult
in failure of the wing centre section
during flight.
! 1. Locate the plywood wing dihedral
brace.Usingaruler,locateitscentral
and draw a vertical line .
Epoxy
central line

ZERO FIGHTER. INSTRUCTION MANUAL
9
INSTALLING THE PILOT.
!1.If you plan on using a pilot in your Zero
fighter .46, now is the time to mount it to the
cockpit floor area of the hatch.
INSTALLINGTHECANOPY.
!1.Locate the canopy and note the trim
lines.Carefullytrimoutthecanopyusingregu-
larscissors.Usecareincuttingout the canopy.
Glueattached.
Securing by 4 machine
screws ( 1mmx 5mm)
for each corner
!2.After cutting out the canopy, trial fit it to
fuselage.Trimas necessary tomakea proper
fit.
!3.After confirming the fit of the canopy to
the fuselage, attach it to the fuselage using
canopy glue. Masking tape can be used to
hold the canopy in place while the glue dries.
Allow the canopy glue to dry.
Glue attachment

ZERO FIGHTER. Instruction Manual
10
INSTALLING THE STOPPERASSEMBLY
!1) Using a modeling knife, carefully cut
off the rear portion of one of the two nylon
tubes leaving 1/2” protruding from the rear of
the stopper. This will be the fuel pick up tube.
!2) Usinga modeling knife, cutone length
of silicon fuel line. Connect one end of the
line to the weighted fuel pickup and the other
end to the nylon pickup tube.
PARTSREQUIRED
FUEL TANK
!{1} Molded NylonFuelTank
!{1} Preassembled Stopper Assembly
!{1} Metal Weighted Pick-Up
!{1} Molded Foam Fuel Tank Support
ADDINGDECALS.
!1.Locatethe decal sheetincludein the kit.
Use the box art photos and some pictures
below as an approximate position reference
for the application of the inclued decals.

ZERO FIGHTER. INSTRUCTION MANUAL
11
!3) Carefully bend the second nylon tube
up at a 45º angle. This tube is the vent tube.
Usealighter or heat guntoheatthe vent tube.
Theventtubemust be heated so itwillbeman
at a 45oangle.
When the stopper assembly is installed in the
tank, the top of the vent tube should rest just
below the top surface of the tank. It should
not touch the top of the tank.
!4) Test fit the stopper assembly into the
tank. It may be necessary to remove some of
the flashing around the tank opening using a
modeling knife. If flashing is present, make
sure none falls into the tank.
!6) When satisfied with the alignment of
the stopper assembly tighten the 3mm x
20mm machine screw until the rubber stop-
per expands and seals the tank opening. Do
not overtighten the assembly as this could
cause the tank to split.
Vent tube
Top of Tank
Fuel Pickup Tube
!5) With the stopper assembly in place,
the weighted pickup should rest about 3/8”
awayfromtherearofthe tank and move freely
insidethetank. Thetopoftheventtube should
rest just below the top of the tank. It should
not touch the top of the tank.
INSTALLING THEFUELTANK
TOOLSREQUIRED
!1) Usingamodelingknife,cutonelengths
of fuel line . Connect one line to the vent tube
and one line to the fuel pick up tube on the
stopper. See picture bellow.
Pushrod Wire

ZERO FIGHTER. Instruction Manual
12
MOUNTINGTHE ENGINE
! !
! !
! 1) Locate the wire pushrod and the nylon
pushrod housing. Install the pushrod housing
through the predrilled hole in the firewall and
into the servo compartment. Make a Z-Bend
1/4" from one end of the plain wire pushrod.
! !
! !
! 2)Temporarilybolttheplatestothemotor
mount, but do not completely tighten them
down at this time. Leave them slightly loose
so they can be moved if needed.
!2) Feed both lines through the fuel tank
compartment and through the predrilled hole
in the firewall. Pull the lines out from behind
the engine, while guiding the fuel tank into
place. Push the fuel tank .
MoldedFoamFuelTank Support
Wood block 4pcs
Pushrod Wire
Glueattached

ZERO FIGHTER. INSTRUCTION MANUAL
13
! !
! !
! 3) Attach the Z-Bend in the pushrod wire
to the throttle arm on the carburetor. You will
need to remove the throttle arm from the car-
buretor to be able to attach the Z-bend. When
complete, reattach the throttle arm to the car-
buretor.
PARTS REQUIRED
COWLING
!{1} Molded Fiberglass Cowling
!{4} 3mm x 12mm Wood Screws
Completely tighten the plates metal
Mufflerexhaust
Cylinderhead
Align the cowling on the fuselage and secure
it with 4 buttom head screws. Do not
overtighten the screw, as this will take away
the vibration.
PROPELLER & SPINNER
Plate metal Pushrod wire

ZERO FIGHTER. Instruction Manual
14
! 2. Position the servos into the servo tray
with the output shafts orientated as shown
below. Drill 1mm pilot holes through the tray
for each of the mounting screws.
PUSHROD SLOT SYSTEM.
PARTS REQUIRED
!{1}Horizontal Stabilizer with Elevator
Halves
Removecoveringatveticalstabilizermounting
slot and horizontal stabilizer mounting slot on
fuselage.
INSTALLING THE FUSELAGE SERVOS
PARTS REQUIRED
!1 Install the switch into the precut hole
in the servo tray. Use the two screws pro-
videdwiththe switch to secureitin place. Drill
two3mmholes through the tray forthescrews
to pass through.
!2 Using a 2mm drill bit, drill a hole
through the side of the fuselage, opposite the
muffler, even with the switch.
INSTALLING THE SWITCH
!3 Make a push-pull lever out of scrap
wire. Attach the wire to the switch lever and
route the wire out the side of the fuselage,
through the hole you drilled.
Some switches come with a hole drilled
through the switch tab for this very pur-
pose. If your switch does not, remove the
switchanddrilla2mmholethrough the middle
of the switch tab.
INSTALLING THE SERVOS
! 1. Install the rubber grommets and brass
collets onto the elevator, rudder and throttle
servos. Testfittheservosinto the preinstalled
servo tray.Because the size of servos differ,
you may need to adjust the size of the precut
openings in the tray.
servos
switch
battery
receiver
Rudder+tail wheel
Elevator
Throttle
horizontal stabilizer mounting slot

ZERO FIGHTER. INSTRUCTION MANUAL
15
Make mark and cut 3 slots for pushrod exit
follow picture below.
Ruller
pen
paper A4 size
Draw 2columns
with 2mm width
5.5 cm
5 cm
Elevator pushrod slot exit
5.5 cm

ZERO FIGHTER. Instruction Manual
16
Fuselage
Connector
TAILWHEEL INSTALLATION.
INSTALLATION THEHORIZONTALSTABILIZER
!1) Using a ruler and a pen, locate the
centerline of the horizontal stabilizer, at the
trailing edge, and place a mark. Use a tri-
angleandextendthismark,from back to front,
across the top of the stabilizer. Also extend
this mark down the back of the trailing edge
of the stabilizer.
Central line
Stearing arm
5 cm
Draw a straight line -
continue with rudder slot
Connector (3 pcs)Connector (3 pcs)Connector (3 pcs)
Connector
Draw pen line
1.2cm
5.5cm
Rudder pushrod slot exit
6cm
Tail wheel pushrod exit slot
Elevator pushrod slot exit

ZERO FIGHTER. INSTRUCTION MANUAL
17
The top of the stabilizer does not have
the hinge pins exposed.
!2) Using a modeling knife, carefully re-
move the covering from over the vertical sta-
bilizermounting slot inthetop of thefuselage.
!3) Slide thestabilizerintoplaceinthepre-
cut slot in the rear of the fuselage. The stabi-
lizer should be pushed firmly against the front
of the slot.
!4) With the stabilizer held firmly in place,
use a pen and draw lines onto the stabilizer
where it and the fuselage sides meet. Do this
on both the right and left sides and top and
bottom of the stabilizer.
!5) Removethe stabilizer. Using thelines
youjust drew asaguide, carefully removethe
covering from between them using a model-
ing knife.
!7) When you are sure that everything is
aligned correctly, mix up a generous amount
of Flash 30 Minute Epoxy. Apply a thin layer
to the top and bottom of the stabilizer mount-
ing area and to the stabilizer mounting plat-
form sides in the fuselage. Slide the stabi-
lizer in place and realign. Double check all of
yourmeasurementsonce more before theep-
oxy cures. Hold the stabilizer in place with T-
pins or masking tape and remove any excess
epoxy using a paper towel and rubbing alco-
hol.
When cutting through the covering to
remove it, cut with only enough pres-
sure to only cut through the covering it-
self. Cutting into the balsa structure may
weaken it.
!6) Using a modeling knife, carefully re-
move the covering that overlaps the stabilizer
mounting platform sides in the fuselage. Re-
move the covering from both the top and the
bottom of the platform sides.
!8) After the epoxy has fully cured, re-
movethe masking tape or T-pinsused to hold
the stabilizer in place. Carefully inspect the
glue joints. Use more epoxy to fill in any gaps
that may exist that were not filled previously
and clean up the excess using a paper towel
and rubbing alcohol.
Remove covering
VERTICAL STABILIZER
INSTALLATION
PARTS REQUIRED
!{1} Vertical Stabilizer with Rudder
pen

ZERO FIGHTER. Instruction Manual
18
!4) Remove the stabilizer. Using a mod-
eling knife, remove the covering from below
the lines you drew. Also remove the covering
from the bottom edge of the stabilizer and the
bottomandtopedgesofthefillerblock. Leave
the covering in place on the sides of the filler
block.
When cutting through the covering to
remove it, cut with only enough pres-
sure to only cut through the covering it-
self. Cutting into the balsa structure may
weaken it.
!5) Slide the vertical stabilizer back in
place. Using a triangle, check to ensure that
thevertical stabilizer is aligned90º to the hori-
zontal stabilizer.
!6) When you are sure that everything is
aligned correctly, mix up a generous amount
of Flash 30 Minute Epoxy. Apply a thin layer
to the mounting slot in the top of the fuselage
and to the sides and bottom of the vertical sta-
bilizer mounting area. Apply epoxy to the bot-
tom and top edges of the filler block and to
thelower hinge also. Setthestabilizerinplace
and realign. Double check all of your mea-
surements once more before the epoxy cures.
HoldthestabilizerinplacewithT-pins or mask-
ing tape and remove any excess epoxy using
a paper towel and rubbing alcohol. Allow the
epoxy to fully cure before proceeding.
90º
Vertical
Stabilizer
Horizontal
Stabilizer
TAIL FAIRING FRB &
RUDDERCONTROLHORNINSTALLATION
! !
! !
! 1) Locate the one nylon control horn.
! !
! !
! 2) Position the rudder control horn on the
left side of rudder. The clevis attach- ment
holesshouldbepositionedoverthehingeline.
ALIGNINGTHEVERTICALSTABILIZER
!1) Using a modeling knife, remove the
covering from over the precut hinge slot cut
intothelowerrearportionofthefuselage. This
slot accepts the lower rudder hinge.
!2) Slide the vertical stabilizerinto the slot
in the top of the fuselage. The rear edge of
the stabilizer should be flush with the rear
edge of the fuselage. The bottom edge of the
stabilizershouldalsobe firmly pushed against
the top of the horizontal stabilizer.
!3) While holding the vertical stabilizer
firmly in place, use a pen and draw a line on
each side of the vertical stabilizer where it
meets the top of the fuselage.
Remove covering
Pen

ZERO FIGHTER. INSTRUCTION MANUAL
19
! !
! !
! 3) Using a 1mm drill bit and the control
horn as a guide, drill the mounting holes
through the rudder .
! !
! !
! 4) Mount the control horns by inserting the
screws through the control horn bases and rudder
then into the mounting backplates. Do Not
overtightenthescrewsorthebackplatesmay crush
the wood.
ControlHorn
MountingScrews MountingPlate
TAIL WHEELPUSHROD INSTALLATION
ELEVATOR VONTROLHORN INSTALLATION
! !
! !
! 1) Locate the one nylon control horn.
! !
! !
! 2) Position the elevator control horn on
the bottom side of elevator. The clevis
attachment holes should be positioned over
the hinge line.
! !
! !
! 5) Installing the tail fairing as same as
picture bellow.
! !
! !
! 5) Rudder pushrod installation as same
as picture below
Pushrod wire
4 pcs machine screws
(2pcs for each side)
Epoxy secure
tail fairing
Tailwheel
pushrod wire
Stearing arm
Tail wheel pushrod
Rudder pushrod.

ZERO FIGHTER. Instruction Manual
20
ControlHorn
MountingScrews MountingPlate
! !
! !
! 3) Using a 1mm drill bit and the control
horn as a guide, drill the mounting holes
through the elevator .
q 4) Mount the control horns by inserting the
screws through the control horn bases and
elevator , then into the mounting backplates.
Do Not overtighten the screws or the
backplates may crush the wood.
Elevator
Rudder
Throttle
WING ATTACHMENT TO FUSELAGE