Seagull cassutt 3M Racer User manual

“Graphics and specifications may change without notice”.
ASSEMBLY MANUAL
MS: 164
Specifications:
Wingspan-----------------------------65in(165cm).
Wingarea---------------1038.5sq.in(67.0sqdm).
Weight----------------------12.1-13.9lbs(5.5-6.3kg).
Length-----------------------------70.8in(179.8cm).
Engine -------------1.2-1.8cu.in-----2-4-stroke.
Engine--------------------------------20cc-26cc
Radio----------4channelswith6digitalservos.

CASSUTT 3M RACER. Instruction Manual
2
INTRODUCTION.
Thankyou forchoosingtheCASSSUTT 3MRACER ARTF by SEAGULLMODELSCOMPANY
LTD. The CASSSUTT 3M RACER was designed with the intermediate/advanced sport scale in
mind. It is a semi scale airplane which is easy to fly and quick to assemble. The airframe is
conventionallybuiltusingbalsa,plywood tomakeitstrongerthantheaverageARTF,yetthedesign
allowstheaeroplanetobekeptlight.Youwillfindthatmostoftheworkhasbeendoneforyoualready.
The motor mount has been fitted and the hinges are pre-installed . Flying the CASSSUTT 3M
RACER 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 CASSSUTT 3M RACER. 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.
If you are inexperienced with basic R/C flight we strongly recommend you contact your R/C
supplierandjoinyourlocalR/CModelFlyingClub.R/CModelFlyingClubsofferavarietyoftraining
proceduresdesigned to helpthenewpiloton his waytosuccessfulR/Cflight.They willalsobeable
to advise on any insurance and safety regulations that may apply.
KIT CONTENTS
1
33
2
2
6
45
7
8
9
10
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ADDITIONAL ITEMS REQUIRED.
1.2-1.8 cu.in 2-4-stroke
20cc-26cc
Radio 4 channels with 6 digital
servos.
Glow plug to suit engine
Propeller to suit engine
Protective foam rubber for radio
system
TOOLS & SUPPLIES NEEDED.
Thick cyanoacrylate glue
30 minute epoxy
5 minute epoxy
Hand or electric drill
Assorted drill bits
Modellingknife
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
INSTALL AILERON CONTROL HORN.
Required Parts
•Wing assembly (left and right)
•Fiberglass control horn(2)
Required Tools and Adhesives
•30-minute Epoxy
Fiberglass control horn.
1) Locate the items for this section of the
manual.
2)Position the Control horn on the Aileron
and use 30-minute Epoxy
Epoxy.
Epoxy.
1 Fuselage
2 Wing set
3 Tail set
4 Cowling
5 Canopy
6 Wing Tube
7. Main landing gear
8. Tailwheel
9. Fiberglass wheel pants
10. Wheels
11. Pilot
12. Hardware bag included
KIT CONTENTS.

CASSUTT 3M RACER. Instruction Manual
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INSTALL RUDDER CONTROL HORN.
Required Parts
•Tail set(Rudder)
•Fiberglass Control horn(2)
Required Tools and Adhesives
•30-minute Epoxy
1) Locate the items for this section of the
manual.
Fiberglass control horn.
2)Position the Control horn on the Tail
set(Rudder) and use 30-minute Epoxy
INSTALL ELEVATOR CONTROL HORN.
Required Parts
•Tail set(Elevator)
•Fiberglass Control horn(2)
Required Tools and Adhesives
•30-minute Epoxy
2)Position the two Control horn on the Tail
set(Elevator) and use 30-minute Epoxy
1) Locate the items for this section of the
manual.
Required Parts
•Fuselage assembly
•Engine mount(left and right)
•Blind nut(4)
•M4x30mm machine screw(4)
•M4 washer(4)
Required Tools and Adhesives
•Phillips screwdriver
•Thread locker glue
ENGINE MOUNT INSTALLATION.
1) Locate the items necessary to install the
engine mount included with your model. .
4x30mm.
2) Usefour4x30mmheadboltsandfour4mm
washers to attach the engine mount rails to
thefirewall.Tighten the screws . Makesure to
use threadlock on the screws to help prevent
them from vibrating loose.
Fiberglass control horn.
Epoxy.
Epoxy.

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Thread locker glue.
3) Carefully bend the second nylon tube
up at a 45º angle. This tube is the vent tube.
1) Using a modeling knife, carefully cut
off the rear portion of one of the 3 nylon tubes
leaving 1/2” protruding from the rear of the
stopper. This will be the fuel pick up tube.
INSTALLING THE STOPPER ASSEMBLY.
2) Usinga modeling knife, cutone length
ofsiliconfuel line. Connect one end oftheline
tothe weighted fuel pickup and the otherend
to the nylon pick up tube.(The silicon tube is
not included).
Required Parts
•Fuselage assembly
•Fueltank
•Fuel tubing,550mm(not included)
•Stopper assembly
•Balsa wood include
•Clunk
Required Tools and Adhesives
•30-minute Epoxy
Venttube. Fuel pick up tube.
Fuel fill tube.
Important: When the stopper assembly is in-
stalled 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.
Carefully use a lighter or heat gun to
permenently set the angle of the vent tube.
AB

CASSUTT 3M RACER. Instruction Manual
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Blow through one of the lines to ensure
thefuel lines have not becomekinked in-
side the fuel tank compartment. Air should
flowthrough easily.
You should mark which tube is the vent
and which is the fuel pickup when you
attach fuel tubing to the tubes in the stopper.
Once the tank is installed inside the fuselage,
it may be difficult to determine which is which.
 7) Slide the fuel tank into the fuselage.
Guide the lines from the tank through the hole
in the firewall.
Fueltank.
C/Aglue.
 8) Use balsa stick to help prevent moveable
from transferring to the fuel tank.
A
B
Fuel pick-up tube. Fuelfill tube.
Vent tube.
 9) Connect the lines from the tank to the
engine and muffler. The vent line will connect
to the muffler and the line from the clunk to the
carburetor.
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.
5) With the stopper assembly in place,
the weighted pick-up should rest away from
therear ofthe tank and move freely inside the
tank. The top of the vent tube should rest just
below the top of the tank. It should not touch
the top of the tank.
6) When satisfied with the alignment of
the stopper assembly tighten the 3 x 20mm
machine screw until the rubber stopper ex-
pands and seals the tank opening. Do not
overtighten the assembly as this could cause
the tank to split.
FUEL TANK INSTALLATION.
Fueltank.
C/Aglue.

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INSTALLING THE FUSELAGE SERVO.
1) Installthe rubber grommetsand brass
colletsontothethrottle servo. Testfit the servo
into the aileron servo mount.
 2) Secure the servos with the screws pro-
vided with your radio system.
Because the size of servos differ, you
mayneedto adjust the size of the precut open-
ing in the mount. The notch in the sides of the
mount allow the servo lead to pass through.
Rudderservo.
Throttleservo.
THROTTLE SERVO ARM INSTALLATION.
Installadjustableservo connectorinthe servo
arm as same as picture below:
AdjustableServo
connector.
Servoarm.
Loctite secure.
1PCS.
Elevatorservoarm.
Rudderservoarm.
Throttleservoarm.
Elevatorservoarm.
Elevatorservoarm.
Required Parts
•Fuselage assembly
Required Tools and Adhesives
•Drill
•Drill bits:2mm
•Phillips screwdrive (small)

CASSUTT 3M RACER. Instruction Manual
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Elevatorservoarm.
Installtheswitch into the precutholeinthe
side of fuselage.
INSTALLING THE SWITCH.
Trimand cut.
Switch.
MOUNTING THE ENGINE.
2) Use a pin drill and 4mm drill bit to drill a
small indentation in the mount for the engine
mounting screw.
 1) Positiontheenginewiththe drivewasher
(150mm) forward of the firewall as shown.
3) Use a drill to drill the four holes in the engine
mount rails.
4mm.
150mm.
Required Parts
•Fuselage assembly
•Switch harness
•M2x10mm socket head screw(2)
Required Tools and Adhesives
•Phillips screwdriver
Required Parts
•Fuselage assembly
•M4 Washer(8)
•Blind nut(4)
•M4x30mm machine screw(4)
•Engine
•1.2mmx600mm rod with nylon housing
•Pushrod connector with setscrew and M2
nuts
Required Tools and Adhesives
•Phillips screwdriver
•Drill bit:4mm
•Pin vise

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4mm diameter.
4) On the fire wall has the location for the
throttle pusshrod tube (pre-drill).
MachineScrewM4x30mm.
Pushrodwire.
7) Slide the throttle pushrod wire into the tube.
Position the engine between the mounts. Use
four 4x30mm machine screws to secure the
engine to the mount as shown.
5) Slide the pushrod tube in the firewall and
guide it through the fuel tank mount. Use
medium C/A to glue the tube to the firewall and
the fuel tank mount.
6) Connect the Z-bend in the 500mm throttle
pushrod to the outer hole of the carburetor arm.
8) Reinstall the servo horn by sliding the
connector over the pushrod wire. Center the
throttle stick and trim and install the servo horn
perpendicular to the servo center line.
9) Move the throttle stick to the closed position
and move the carburetor to closed. Use a 2.5mm
hex wrench to tighten the screw that secures
the throttle pushrod wire. Make sure to use
threadlock on the screw so it does not vibrate
loose.
Screw.
Pushrod tube hole .

CASSUTT 3M RACER. Instruction Manual
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1) Locate the items neccessary to install
thewheel and wheel pantstothe landing gear
as shown.
WHEEL AND WHEEL PANTS
INSTALLATION.
2) Follow diagram below for wheel pant
installation:
Use a drill and 4.2mm drill bit to drill a hole in
the wheel pants.
wheel collar.
wheel.
Axle.
Washer. M3.
wheel Pant.
wheel.
M3.
M3.
wheel collar.
nut. Axle.
Washer.
M3.
4) Slidethecollarto the axle and setscrew
the collars to secure the collar to the axle and
thensliderthe wheel on theaxlewith a drop of
oilontheaxleso thewheelwillspin freelywhen
installed. Prepare a second collar and tighten
the setscrew using hex wrench to secure the
collar to the axle.
5) Place the wheel assembly in the wheel
pants. The threaded portion of the axle will fit
the notch of the wheel pant as shown.
6) Slide the threaded end of the axle
through the hole in the bottom of the landing
gear leg. Use a washer and locknut to tighten
the axle to the landing gear. Make sure to use
threadlock on the nut so it won’t vibrate loose
in flight as shown.
Required Parts
•Fuselage assembly
•Landing gear (2)
•Washer (2)
•Axle(2)
•Plywood washer (2)
•Wheel collar (4)
•Wheel pant(right and left)
•Wheel(2)
Required Tools and Adhesives
•Drill
•Drill bits:4mm
•Phillips screwdrive (large)
8mm.
14mm.
3) You have to trim each axle using a tool
cutting and cut-off wheel.
Caution when cutting the axles and
wear protective goggles.
Drill a hole.

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C/Aglue.
LandingGear. wheel Pant.
Lockerglue.
 7) Tighten the setcrews using a hex
wrench to secure the collars on the axle over
the flat spot to retain the wheel as shown.
Repeat steps as above to attach
remaining wheel pants to the landing gear.
C/Aglue.
INSTALLING THE MAIN LANDING GEAR
TO FUSELAGE.
 8) The blind nuts for securing the landing
geararealready mounted inside thefuselage.
 9) Using the hardware provided, mount
the main landing gear to the fuselage.
Required Parts
•Fuselage assembly
•M4 Washer (4)
•M4x20mm socket head screw(4)
Required Tools and Adhesives
•Phillips screwdrive
•Thread locker glue
Drill a hole.

CASSUTT 3M RACER. Instruction Manual
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COWLING INSTALLATION.
1) Slide the fiberglass cowl over the
engine and line up the back edge of the cowl
withthemarks you made onthefuselage then
trim and cut as shown.
2) While keeping the back edge of the
cowl flush with the marks, align the front of
thecowl with the crankshaft of theengine. The
front of the cowl should be positioned so the
crankshaft is in nearly the middle of the cowl
opening.Use thespinnerbackplateasa guide.
Hold the cowl firmly in place using pieces of
masking tape.
Becauseofthe size of thecowl,it may be nec-
essaryto use a needlevalve extension forthe
highspeedneedlevalve. Make this out of suf-
ficient length 1.5mm wire and install it into the
end of the needle valve. Secure the wire in
placeby tightening the setscrew in the sideof
the needle valve.
Required Parts
•Fuselage assembly
•Fiberglass cowlinh
•M3x10mm machine screw(4)
Required Tools and Adhesives
• Pin sive
•Phillips screwdrive
 10) Place the fuselage inverted on the
workbenchina suitable stand. Setthelanding
gear in place and use a screwdrive to secure
the landing gear to the fuselage using bolts
M4x20mmandwashers.Makesuretouse the
threadlock on the bolts so they don’t vibrate
loose.
Thread locker glue.
Trim and Cut
Trim and Cut

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The propeller should not touch any part
of the spinner cone. If it does, use a
sharp modeling knife and carefully trim away
the spinner cone where the propeller comes
in contact with it.
ELECTRIC POWER CONVERSION.
SPINNER INSTALLATION.
Install the spinner backplate, propeller and
spinner cone.
Required Parts
•Fuselage assembly
•Fiberglass cowlinh
•Spinner assembly
•M3x10mm machine screw(4)
Required Tools and Adhesives
•Phillips screwdrive
Servos. Smallweight.
Thread.
INSTALLING THEAILERON.
Required Parts
•Wing assembly(left and right)
•Servo with hardware (2)
•M2x12mm machine screw(8)
Required Tools and Adhesives
•Phillips screwdrive
•30-mminute epoxy
String.
Small weight.
1) Usinga small weight (Weightedfuel pick-up
workswell) andstring, feedthestring through
the wing as indicated.
2) Place the servo between the mounting
blocksandspaceitfromthehatch.Useapencil
to mark the mounting hole locations on the
blocks.
Because the size of servos differ, you
mayneed toadjustthesizeof theprecutopen-
ing in the mount. The notch in the sides of
themountallowtheservoleadtopassthrough.
MachineScrew M3x10mm
 3) Install themuffler and muffler extension
onto the engine and make the cutout in the
cowl for muffler clearance. Connect the fuel
and pressure lines to the carburetor, muffler
and fuel filler valve. Secure the cowl to fuse-
lage using the 3x10mm screws to tighten the
screws.
Needlevalve.

CASSUTT 3M RACER. Instruction Manual
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4) Apply 2-3 drops of thin C/A to each of the
mounting holes. Allow the C/A to cure without
using accelerator.
5) Use dental floss to secure the connection
so they cannot become unplugged.
6) Secure the servo to the aileron hatch using
Phillips screwdriver and the screws provided
with the servo.
7) Apply 1-2 drops of thin C/A to each of the
mounting tabs. Allow the C/A to cure without
using accelerator.
8) A string has been provided in the wing to
pull the aileron lead through to the wing root.
Remove the string from the wing at the servo
location and use the tape to attach it to the
servoextensionlead. Pull the lead throughthe
wing and remove the string.
3) Use drill bit in a pin vise to drill the mouting
holes in the blocks.

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9) Set the aileron hatch in place and use a
Phillips screw driver to install it with four wood
screws.
Wing. M2lock nut.
Aileron.
M3 lock nut.
M3clevis.
50mm.
70mm.
AILERONPUSHRODHORNINSTALLATION
Required Parts
•Wing assembly(left and right)
•2.6mmx50mm threaded rod(2)
•3mm metal clevis with silicone tubing(4)
•Lock nut(4)
Required Tools and Adhesives
•Phillips screwdrive
•30-mminute epoxy
M2x10mm.

CASSUTT 3M RACER. Instruction Manual
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Remove covering.
INSTALLING THE HORIZONTAL
STABILIZER.
Draw center line.
Required Parts
•Fuselage assembly
•Tail Set(Rudder and Elevator)
Required Tools and Adhesives
•Ruler,Pen,Knife
•30-mminute epoxy
 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.
 3) Slide the stabilizer into place in the pre-
cut slot in the rear of the fuselage. The stabi-
lizer should be pushed firmly against the front
of the slot.
1) Using a ruler and a pen, locate the
centerlineofthehorizontalstabilizer,atthetrail-
ing edge, and place a mark. Use a triangle
and extend this mark, from back to front,
across the top of the stabilizer. Also extend
thismark down theback of the trailingedge of
the stabilizer.
2)Using amodelingknife,carefully remove
thecoveringatmounting slot of horizontalsta-
bilizer ( both side of fuselage).
 5) Remove thestabilizer. Using the lines
youjust drew asaguide, carefully removethe
covering from between them using a model-
ingknife.
Aileron.
Wing.Wing.
Repeat the procedure for the other aileron servo.
Aileron.

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 7) When you are sure that everything is
aligned correctly, mix up a generous amount
of 30 Minute Epoxy. Apply a thin layer to the
topandbottom of thestabilizermounting area
and to the stabilizer mounting platform sides
in the fuselage. Slide the stabilizer in place
and realign. Double check all of your mea-
surementsoncemorebefore the epoxy cures.
Holdthe stabilizerin place withT-pinsormask-
ing tape and remove any excess epoxy using
a paper towel and rubbing alcohol.
Required Parts
•Fuselage assembly
•Tail Set(Rudder and Elevator)
Required Tools and Adhesives
•Ruler,Pen,Knife
•30-mminute epoxy
INSTALLING VERITICAL FIN.
1) Using a modeling knife, remove the
covering from over the precut hinge slot cut
into the lower rear portion of the fuselage.
Remove covering.
Fill epoxy.
2) 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.
Fill epoxy.
Fill epoxy.
Remove covering.
Whencuttingthroughthecovering to re-
move it, cut with only enough pressure
toonly cut through the coveringitself. 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.
Fill epoxy.
Fill epoxy.

CASSUTT 3M RACER. Instruction Manual
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RUDDER AND ELEVATOR PUSHROD
HORN INSTALLATION.
2)Install the rudder andelevator control horn
using the same method as with the rudder
and aileron control horns.
3) Position the rudder and elevator control
horn on the both side of rudder and elevator.
4) When you are sure that everything is
alignedcorrectly, mix up a generous amountof
Flash30MinuteEpoxy. Applyathinlayertothe
mounting slot and to bottom of the vertical sta-
bilizer mounting area. Apply epoxy to the bot-
tomand top edges ofthe filler blockand tothe
lower hinge also. Set the stabilizer in place
andrealign. Double checkallofyourmeasure-
mentsonce more beforetheepoxycures.Hold
the stabilizer in place with T-pins or masking
tape and remove any excess epoxy using a
papertowel and rubbingalcohol. Allowthe ep-
oxy to fully cure before proceeding.
Required Parts
•1000mm Cable(2)
•2.6mmx80mm threaded rod(2)
•M3 metal clevis with silicone tubing(8)
•Lock nut(4)
•Cable lock(8)
M3 lock nut.
M3 clevis.
100mm.
80mm.
1
1) Locate the items for this section of the
manual.
90º
Vertical
Stabilizer.
Horizontal
Stabilizer.
3) Slide the vertical stabilizer back in
place. Using a triangle, check to ensure that
thevertical stabilizer is aligned90º to thehori-
zontal stabilizer.
Elevator pushrod.
Rudder pushrod.
2pcs.
2pcs.

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MOUNTING THE TALI WHEEL.
Required Parts
•Fuselage assembly
•Tail wheel assembly
•M3 Washer(2)
•M3x30mm socket head screw(2)
•M3x25mm machine screw(2)
Required Tools and Adhesives
•Phillips screwdrive
•30-minuteepoxy
•Drill
1) Locate the items for this section of the
manual.
3 x 30mm.
3x25 mm.
Aluminum tail
landing gear.
5) Elevator and rudder pushrods assembly
as pictures below.
4)Thread one clevis and M3 lock nut on to
each rudder and elevator control rod. Thread
the horns on until they are flush with the ends
of the control rods.
CableSteering Elevator pushrod.
CableSteering
Elevator pushrod.

CASSUTT 3M RACER. Instruction Manual
20
- Apply a bead of canopy glue around the inside
edge of the canopy. Position the canopy onto
the hatch. Use tape to hold the canopy secure
until the glue fully cures.
3) Position the canopy onto the fuselage. Trace
around the canopy and onto the fuselage using
a felt-tipped pen.
4) Install the canopy and secure it with M2x6mm
screws.
25mm
INSTALLATION PILOT.
1) A scale pilot is included with this ARF. The
Seagull Pilot included fitting well to the cockpit.
(or you can order others scale pilot figures
made by Seagull factory. They are available at
Seagull distributors.)
If you are going to install a pilot figure, please
use a sanding bar to sand the base of the figure
so that it is flat.
2) Position the pilot figure on the canopy floor
as show. Locate the oval shaped on the canopy
floor and remove the covering. Use epoxy to
glue this into the base of the pilot figure, please
see pictures as shown.
Required Parts
•Fuselage assembly
•Canopy
•Pilot
•M2x6mm machine screw(6)
Required Tools and Adhesives
•Phillips screwdrive
•30-minuteepoxy
•Ruler
Epoxy.