SIG SIGRC44 User manual

Sig Mfg. Co., Inc...401
-
7 S Front St ...PO Box 520....Montezuma IA 50171
-
0520
Welcome to the sport of Radio Control flying, and thank you for choosing the SIG KADET LT-40.
We understand how anxious you are to get started building and flying your KADET LT-40, but please take a few minutes right
now to study the full-size plans while you page through these instructions. This will familiarize you with the general layout of the
airplane and the building sequence, making the entire project easier in the long run.
Introduction
In order for your KADET LT-40 to fly as well as it was designed to, it must be carefully assembled. A model airplane that is not
built properly will not fly properly! Remember to work slowly and follow the instructions exactly. SIG, as the kit manufacturer, can
provide you with a proven aerodynamic design, quality materials, and detailed instructions, but ultimately the flyability of your
finished model depends on how well YOU put it all together.
Customer Service
SIG Mfg. Co., Inc. is totally committed to your success in building and flying the KADET LT-40. Should you encounter any
problem building this kit, or find any missing or damaged parts, feel free to contact us by mail or phone.
SIG MFG. CO., INC.
401-7 S Front St
P.O. Box 520
Montezuma, IA 50171-0520
SIG MODELER
’
S HOTLINE: 1
-
641
-
623
-
0215 Weekdays, 7:00am
-
4:30pm Central

.
WARNING! THIS IS NOT A TOY!
Flying machines of any form, either model-size or full-size, are not toys! Because of the speeds that airplanes must
achieve in order to fly, they are capable of causing serious bodily harm and property damage if they crash. IT IS YOUR
RESPONSIBILITY AND YOURS ALONE to assemble this model airplane correctly according to the plans and
instructions, to ground test the finished model before each flight to make sure it is completely airworthy, and to always
fly your model in a safe location and in a safe manner. The first test flights should be made only with the assistance of
an experienced R/C flyer.
The governing body for radio-control model airplanes in the United States is the ACADEMY OF MODEL
AERONAUTICS, sometimes referred to as the AMA. The AMA SAFETY CODE provides guidelines for the safe
operation of R/C model airplanes. While AMA membership is not mandatory, it is a good idea and we encourage all
new R/C fliers to join the AMA. Membership in the AMA provides you with important liability insurance protection in
case your R/C model should ever cause serious property damage or personal injury to someone else.
For more information, contact:
ACADEMY OF MODEL AERONAUTICS
5161 East Memorial Drive
Muncie, IN 47302
Phone: [phone]
Limit of Liability
The craftsmanship, attention to detail, and actions of the builder/flyer of this model airplane kit will ultimately determine the flight
performance and safety of the finished model. SIG MFG. CO.’s only obligation shall be to replace those parts of the kit proven
to be defective or missing. The user shall determine the suitability of the product for his or her intended use and shall assume all
risk and liability in connection therewith.
COMPLETE KIT PARTS LIST
Die-Cut Balsa Wood Sheets
2 Sheet No. 1: wing ribs W1, W2 2 Sheet No. 2: wing ribs
W3, W4
8 Sheet No. 3: wing ribs W5 2 Sheet No. 4: wing sheeting
WS-T1, WS-B1
1 Sheet No. 5: wing sheeting WS-T2, WS-B2 1 Sheet No. 6: wing
sheeting WS-T3, WS-B3
Die-Cut Plywood Sheets
2 Sheet No. 7: FS-R uselage side rear, F8
uselage ormer
2 Sheet No. 8: FD uselage
doubler, HATCH TONGUE
1 Sheet No. 9: FB-F uselage
bottom ront, FB-R uselage
bottom rear
1 Sheet No.10: FT-R uselage top
rear, HATCH, WINDSHIELD
1 Sheet No.11: F4 uselage ormer, F5
uselage ormer, DTG dihedral tip gauge,
DRG dihedral root gauge
1 Sheet No.12: F7 uselage
ormer, TANK FLOOR
2 Sheet No.13: FS-F uselage side
ront, WTP wing tip plate
1
Sheet No.14: ASM aileron servo
mount, FSM uselage servo
mount
Sawn Balsa Wood Parts
1 5/16"x6"x3" STAB CENTER SECTION
Sawn Plywood Parts
2 1/16"x1"x3-5/16" TRAILING EDGE
STIFFENER
Laser-Cut Parts
2 1/8" thick balsa wood SW-1, SW-2, SW-3
shear webs
1 5/16" thick balsa wood
STAB L.E. JOINER
2 1/8" thick birch plywood MADB
main dihedral brace
1 1/4" thick birch plywood F1
irewall
1 1/8" thick lite-ply F2 uselage ormer 1 1/8" thick lite-ply F3
uselage ormer
1 1/8" thick lite-ply F6 uselage
ormer
Balsa Wood Sticks
4 1/4"x3/8"x36" REAR SPARS, TOP &
BOTTOM
4 1/4"x1/2"x10-1/8" SPAR
DOUBLERS, TOP &
BOTTOM
2 5/16"x5/16"x36" STABILIZER
PARTS, FIN PARTS
3 5/16"x1/2"x36" STABILIZER
PARTS, FIN PARTS
2 3/8"x3-13/16" BALSA TRIANGLES or
irewall support
Special Pre-Shaped Balsa Wood Parts
2 TRAILING EDGES 2 LEADING EDGES 2 AILERONS 2 CENTER SECTION TRAILING
EDGE
1 RUDDER 1 ELEVATOR

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Hardwood Parts
4 1/4"x1/2"x36" MAIN WING SPARS,
TOP & BOTTOM
1 3/8"x1"x3-1/2" GROOVED
LANDING GEAR BLOCK
2 1/2"x1"x1" L.G. ANCHOR BLOCKS
(in Hardware Pack #1)
2 5/16" dia. x5-1/2" DOWELS (in
Wire Parts Pack)
Wire Parts Pack
2 MAIN GEAR WIRES, pre-bent 1 NOSE GEAR WIRE, pre-bent 1 RIGHT AILERON TORQUE ROD
w/BRASS BEARING, pre-bent
1 LEFT AILERON TORQUE ROD
w/BRASS BEARING, pre-bent
2 1/16" dia. x18" STRAIGHT MUSIC
WIRE
6 10" THREADED STEEL RODS
(threaded one end)
Hardware Pack #1
4 4-40 x1/2 MOUNTING BOLTS
(Slotted Round Head)
4 4-40 x1 MOUNTING BOLTS
(Slotted Round Head)
4 6-32 x3/4 MOUNTING BOLTS
(Slotted Round Head)
4 4-40 AIRCRAFT LOCK NUTS
4 4-40 BLIND NUTS 4 6-32 BLIND NUTS 1 6-32 x1/4 SELF-TAPPING SCREW
(Slotted Panhead)
5 #2 x1/2 SHEET METAL SCREWS
(Slotted Panhead)
4 #4 x1/2 SHEET METAL SCREWS
(Slotted Panhead)
1 #2 FLAT METAL WASHER 1 NYLON NOSE GEAR BEARING 1 NYLON STEERING ARM
1 NYLON CONTROL HORN, MEDIUM 1 NYLON CONTROL HORN,
SMALL
2 NYLON LANDING GEAR STRAPS 2 NYLON AILERON CONNECTORS
6 NYLON R/C LINKS 2 R/C SOLDER LINKS
Hardware Pack #2
2 GLASS-FILLED ENGINE MOUNTS 1 Bag o 4 complete PUSHROD
CONNECTORS
1 Bag o 6 complete 5/32" WHEEL
COLLARS
1 Bag o 15 SIG EASY HINGES
Miscellaneous Parts
1 FIBERGLASS CLOTH TAPE, 1"x24" 1 SILICONE FUEL LINE, 12"
long
2 SMALL DIA. NYLON PUSHROD
TUBING, 1/8" O.D. x12" long
2 SMALL DIA. NYLON PUSHROD
TUBING, 1/8" O.D. x38" long
2 LARGE DIA. NYLON PUSHROD
TUBING, 3/16" O.D. x26-5/8" long
1 2" dia. SIG SPINNER,
complete
1 8 ounce DU-BRO FUEL TANK,
complete
2 3" dia. KAVAN MAIN WHEELS
1 2-3/4" dia. KAVAN NOSE WHEEL 1 LEFT DECAL SHEET,
DKM#267A
1 RIGHT DECAL SHEET, DKM#267B
Documenation
1 PLAN SHEET 1 1 PLAN SHEET 2 1 "INSTRUCTION BOOK" 1 "TIPS ON USING SIG CA"
1 "THE BASICS OF RADIO CONTROL"
Wood Parts Identification
Wood parts such as standard stick and sheet stock, leading edges, trailing edges, ailerons, elevator, etc., are all easily
identifiable by comparing their shape and dimensions to the plans and the KADET LT-40 COMPLETE PARTS LIST; therefore
we did not feel that there was any need to label these parts. On the other hand, proper identification of the different wing ribs,
wing sheeting, fuselage formers, etc., can be confusing because some of them are very similar looking, but in fact they are quite
different. Wherever possible, we have labeled (printed) these parts. The die-cut plywood parts are not labeled. They can be
identified using the plans and the KEY TO DIE
-
CUT PLYWOOD PARTS.
Use a pencil to label each part with its name or number,
before removing the parts from the die-cut sheets. Use
the KEY TO LASER-CUT PARTS to identify and label
the following laser-cut parts: STAB L.E. JOINER, MADB,
F1, F2, F3, and F6. Use the SHEAR WEB
IDENTIFICATION DIAGRAM to identify and label the
sawn balsa wood SHEAR WEBS SW-1, SW-2, and SW-
3.
Be careful when removing parts from die-cut sheets. If
difficulty is encountered, do not force the part from the
sheet - use a modeling knife to cut it free. Handle the
removed parts carefully, as long parts (such as the
fuselage sides) are fragile until glued into a structural
unit. Sort the different parts into individual piles to avoid
confusion during building. Save all scrap wood until the
model is finished. You never know where a small piece
of scrap wood may come in handy during construction.

.
NOTE: The edges of all the laser-cut parts have a "burnt" appearance varying from light brown to dark black, depending upon
the thickness and type of material the part is made of. Our tests indicate that a slight discoloration of the edges does not
significantly affect the bonding ability of these parts. The lightly discolored parts F2, F3, F6, MADB, and Stab L.E. Joiner can be
installed as is, without any need to try to clean the edges. However we recommend that the black edges of former F1, made of
1/4" thick plywood, be lightly sanded with an 80 grit sanding block to remove the loose black soot. It's not necessary to sand
every bit of black off (you don't want to change the size of the part). Sand until you can run your finger lightly over the edge
without picking up any black color (see photos of sanded F1 in the fuselage section).

.
About The Wood In The Kit
We strive to supply good quality materials in all SIG kits. However wood is a highly variable material (unlike man-made plastic
or metal), so every single wood part in a kit will probably not have flawless appearance. Often things that look like an
imperfection are actually quite acceptable when you consider the function the part will serve. Mineral stains and tiny knots do
not seriously affect balsa wood strength. Also, there is a natural tendency for some balsa sticks and sheets to immediately bow
upon being cut off from a perfectly square block due to internal stresses in the wood. In most cases, bows in wood parts (such
as leading edges) readily straighten out as they are glued into a structural unit. Likewise Lite-Ply fuselage sides, formers, and
doublers that are warped will usually straighten right out when they are glued in place. If you are in doubt about the suitability of
any part in your kit for it
’
s intended purpose, call or write to us for assistance and/or a replacement part.
Additional Components Needed
The following items are not supplied in this kit but are needed to complete the KADET LT-40. Because of the wide variety of
brands available and the influence of personal preferences, the choice of these items is left to the builder to select.
-
.
30 to .40 cu. in. 2
-
Stroke Glow R/C Engine w/Muffler, or .40 to .50 cu. in. 4
-
Stroke Glow R/C Engine w/Muffler
Engines larger than those listed are not recommended! Use of oversize engines will cause balance problems and may
overload the structure of the airplane. The KADET LT-40 has a light wing loading and does not need a super "hot" engine to
fly well! Any normally ported .40 2-stroke glow R/C engine will provide adequate power to fly the KADET LT-40. We believe
that the .40 2-stroke glow R/C engine will be the most commonly used engine in the KADET LT-40, so that is what we’ve
shown on the full-size plans and in this instruction book.
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Propeller
Propellers are a subject that can fill a book all by themselves! There are a large variety of propeller sizes available, and
selecting the best one to use on your KADET LT-40 will depend mostly on which engine you end up buying. Refer to the
instruction sheet that comes with your engine for a recommended propeller size. If the engine manufacturer lists several
possible sizes, pick the one that sounds like it is for a slower flying model - choose "sport or scale" instead of "pattern or
racing". Also, be sure to read "THE BASICS OF RADIO CONTROL" book for more tips on propellers. As a general rule, if
you are going to use a normal .40 2-stroke glow R/C engine in your KADET LT-40, you will undoubtedly use a 10-
6 propeller,
as noted on Plan Sheet 1.
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Radio Control System
You will need a (minimum) 4-
channel radio control system with 4 servos to operate the ailerons, elevator, rudder, and engine
throttle of your KADET LT-40. The KADET’s fuselage is spacious enough that any common brand of radio equipment with
standard size servos and battery pack can be used. Be certain that your radio system transmits on one of the FCC-approved
frequencies for R/C model aircraft. See "THE BASICS OF RADIO CONTROL" book for more information on radio equipment
and frequencies.
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1/2"x8"x12" Soft Foam Rubber (such as SIGRF
-
240)
Used to protect your radio receiver and battery pack from damaging engine vibration. Also used as packing around the fuel
tank and radio components to keep them from shifting around in flight.
-
#
67 Rubber Bands (such as SIGSH
-
747)
Used to hold the wing on the fuselage. Always use at least 12 rubber bands when flying. Replace any bands that have
stretched out or have become oil soaked.
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3 Rolls of Covering Material (such as SIG AEROKOTE COVERING)
Although the KADET LT
-40 can be finished with a wide variety of covering materials (some which need to be painted and
some which don’t), this instruction book assumes that the beginner will use one of the popular pre-finished iron-
on plastic film
coverings. In the Covering and Finishing section of these instructions you will find a "COVERING CUTTING DIAGRAM"
which shows how to cut 3 standard (26" wide x 6 ft. long) rolls of iron
-
on film covering to fit the KADET LT
-
40.
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4 oz. of Fuel
-
Proof Paint (such as SIG SUPERCOAT DOPE)
For fuel-proofing the engine compartment, tank area, wing saddle, and ends of the wing dowels.

.
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Light
-
Weight Wood Filler
For filling holes, nicks, and dents after assembly of the model, but before covering. Regular household "wall repair" or
"spackling" compound (3M, Red Devil, DAP, etc.) works well for this. There are also several excellent "model fillers" available
at the hobby shop. Just make sure whatever you use is light weight and sands easily. Do not use household patching plaster
-
it
’
s way too heavy!
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Glue
There are so many different types of glue available today for model airplane construction that it can be confusing to even the
experienced modeler. To simplify matters, most model airplane glues can be classified as one of four basic types:
1. Cyanoacrylate Adhesives, such as SIG CA, are very strong and bond in just seconds. Dramatically speeds up
building time! Different vicosity’s and cure times are available to suit all areas of model construction.
2. Two-Part Epoxy Glues, such as SIG-KWIK-SET (5-minute cure) and SIG EPOXY (3-
hour cure), are super strong but
too heavy for general construction. Often used in high stress areas such as the firewall, landing gear, and wing
joiners.
3. Water-Based Glues, such as SIG-BOND (aliphatic resin), are very safe and easy to use. Excellent for general
construction, although somewhat slow drying.
4. Solvent-Based Model Cement, such as SIG-
MENT, is the oldest form of traditional model airplane glue. Still used for
general construction by some modelers
-
especially when building super light weight free flight models.
You could build the KADET LT-40 using any of these four basic types of glue. Each type has different characteristics and
advantages, and all of them will result in a bond that is stronger than the wood materials being glued together. Often times the
choice of which type to use boils down to a matter of personal preference based on past experience. However, if you want to
get your KADET LT-40 into the air as quickly as possible, we recommend that you use CA glue for the majority of the assembly
of this kit. CA glue is not only fast and strong, but it also makes it possible to do some unique things in the construction
sequence. For instance, since CA glue has the ability to penetrate into an already assembled joint, we can first assemble the
interlocking fuselage parts "dry" (without glue), then check and adjust the alignment, and finally apply CA to the pre-assembled
joints. This makes it very easy to build a straight and true fuselage in a very short time. If the use of CA glues is new to you,
please read "TIPS ON USING SIG CA", included in this kit.
NOTE:
The instructions in this book are written assuming the use of MEDIUM CA glue for all steps, unless otherwise noted. In
other words, if an instruction simply says "glue" part A to part B - use MEDIUM CA! If THIN CA, SLOW CA, EPOXY
GLUE, or SIG-BOND GLUE would work better in a specific instance, we will call for it.
Workshop Tools And Supplies
As the old saying goes, "Having the right tool makes the job easy". That certainly holds true with building model airplanes as
well as anything else. Below is a list of the tools we feel are the minimum required to speedily and accurately assembly this kit,
and to build other model airplanes in the future. Some of them are common household tools that you probably already have,
while some are special "modeling" tools that you will have to purchase at the hobby shop. While there are many more special
modeling tools available, and they all do a wonderful job in certain areas, these are the basics with which to get started in the
hobby. Like the rest of us, eventually you will add others to your workshop as the need arises.
-
Building Board
-
12"x36" minimum size
- This can be any flat surface that will accept and hold pins - such as insulation
board, foam board (cardboard laminated to both sides of a foam sheet), cork bulletin board, soft plywood, a reject "door core"
from the lumber yard, etc. The most important thing is that the board must be perfectly flat and untwisted! Your wings
and tail surfaces will be built on this board, and if the board is twisted or bowed, the parts you build on it will assume the
same shape and your model will not fly properly.
NOTE:
The building board you’ll see us using in the photos in this book is an 18" x 48" piece of 3/4" thick plywood (perfectly
flat!), with a same sized piece of 1/4" thick foam board stuck down on top of the plywood with double-sided sticky tape.
The plywood provides the rigidity and flatness we need, and the semi-flexible foam board lays flat on the plywood and
gives us a surface to push pins into. All materials were obtained from the local lumber yard. Insulation board or cork
sheet would make a good substitute for the foam board, if that is not available.

.
-
Wax Paper
Used to cover the plans so that parts are not accidentally glued to them.
- A Few Dozen T-Pins (such as SIGSH-310)
For holding parts together during construction.
- Masking Tape or Scotch Tape
For holding parts together during construction.
- #32 or #64 Rubber Bands (such as SIG #SH-364 or SIG #SH-366)
Used to hold the fuselage parts together during initial assembly.
-
Scissors
-
Ruler or Tape Measure
- Pencil
Do not use a ball-point or felt-tip pen for making marks on the model during construction. If not sanded off, ink marks may
show through the model
’
s final finish. Use a pencil instead of a pen.
- Modeling Knife (such as X-Acto #1 knife with extra #11 blades)
For general cutting.
- Razor Saw (such as X-Acto #75300 or Zona #500)
For cutting thicker wood pieces.
- 1/2-Dozen Single-Edge Razor Blades (such as SIG #SH-283)
For cutting and trimming covering material.
- Long Metal Straight Edge (such as SIG #SE-236)
To aid in making long straight cuts in wood and covering material.
- Triangle (such as metal SIG #TR-036 or plastic draftsman’s triangle)
For squaring up parts during assembly and to aid in making short straight cuts in wood and covering material.
-
Assorted Screwdrivers
-
Assorted Hex "Allen" Wrenches
-
Regular Pliers
-
Drill and 1/16", 3/32", 1/8", 5/32", 5/16" Drill Bits
-
Needle
-
Nose Pliers with cutting jaws
- Flat File
For cutting, bending, and shaping pushrod wires. For removing burrs and sharp edges from wire parts.
- Soldering Iron, Rosin Core Solder, and Soldering Paste Flux
There is one part in this kit that needs to be soldered. (If you don’
t have a soldering iron, perhaps you can borrow one for this
part of the construction.)
- Covering Iron
For applying iron-on covering material. Although a household iron can be used to apply covering, smaller easier-to-use irons
specifically designed for model covering are available at the hobby shop. (Like the soldering iron, perhaps you can borrow
one from another modeler if you are covering your first airplane.)
- 80 and 220 Grit Sandpaper
We prefer either garnet or silicone carbide type open-coat sandpaper. Use the 80 grit to rough sand and shape parts. Use
the 220 grit to fine sand the entire model prior to covering. Sand with the grain of the wood whenever possible. Always use
fresh, sharp sandpaper. Sharp sandpaper will cut through glue and hard materials easily, giving an even surface. Dull
sandpaper will require more pressure and may gouge the surface.

.
-
Sanding Blocks
The instructions will call for you to sand some parts of the model using a "sanding block", which is simply a piece of
sandpaper backed up by a solid, flat block of wood, plastic, or whatever. A sanding block will give you a much flatter, truer
result than you would get with an unbacked, limp piece of sandpaper held in your fingertips. An assortment of different size
sanding blocks are indispensable tools for all model construction. There are many styles of commercially made sanding
blocks available in hobby shops, or you can make your own.
A good general purpose sanding block can be made by wrapping a full
-size
standard 9"x11" sheet of sandpaper around a piece of hardwood or plywood, as
shown below. This is the most commonly used sanding block in our workshop!
Use screws or thumbtacks along one edge to hold the overlapped ends of the
sandpaper in place. Put 80 grit sandpaper on the block during general
construction, and then switch to 220 grit sandpaper for final sanding just before
covering (or make yourself two of these blocks, one for each grit sandpaper).
There will be other times when a slightly smaller sanding block is easier to
manage. Also, you can make a small sandpaper "file" by simply gluing a strip of
80 grit sandpaper onto a scrap plywood stick. Sandpaper glued or taped to
different size hardwood dowels are great for sanding inside curves and holes.
Last but not least, for sanding really large areas, glue 80 grit sandpaper onto a 24" or 36" long piece of aluminum "channel"
or "T
-
Bar" stock (most hardware stores carry a rack of aluminum extrusions in various sizes and shapes).
How To Use These Instructions
Like a full-size airplane, the KADET LT-40 is built by first constructing several basic structures - the FUSELAGE, WINGS,
STABILIZER, FIN, etc. - which are then assembled into a completed airplane. These instructions will take you step-by-step
through the construction of each basic structure and then the final assembly.
How To Use The Plans
There are two sheets of Plans included in this kit. The plans will be used in several ways. They will help you identify all the
parts and determine the relationship of all the parts to each other. They will also be used as a building pattern for the Wing
Panels, Stabilizer, and Fin -
which will be assembled directly on top of the plans. The plans also show how we would install a
typical radio and engine in the KADET LT-
40. By referring to the examples shown on the plan, you should be able to properly
install your radio and engine, even if they are not exactly the same as what is shown on the plan.
Everything on the plans is drawn FULL-SCALE, or ACTUAL SIZE (except for the Wing Front view which is half-size) to show
the correct size, shape, and relationship of all the parts to each other.
The plans show the model completely assembled. Unfortunately this often
covers up the important parts inside the model, making it hard to understand
how things fit together. In normal drafting practice, parts hidden inside the
model would be shown with dashed lines, and you will find many areas of the
plan that do use this method. However in areas where there are so many
hidden parts that it would be confusing to use so many dashed lines, we have
elected to use "cutaway views". Cutaway views make it appear as if a portion
of a part has been cut out and removed. This is done to clearly show the parts
that are immediately under the cutaway part. For instance, on Plan Sheet 1
we have used a cutaway to completely remove almost all of the left fuselage
side (starting between Formers F4/F5 and going forward) so that the details
inside the fuselage could be clearly seen. On Plan Sheet 2 there are several
small cutaways in the wing sheeting to allow details underneath to be clearly seen.
NOTE: The cutaways on the plan do not mean that the parts should actually be shaped that way!
Whenever building a structure directly on top of the plans (like the Wing Panels, Stabilizer, or Fin), you must first tape or pin
the plan onto your building board and then cover it with a layer of wax paper. The wax paper will keep excess glue from
sticking the model parts to the plans. As you add parts to the structure, any parts which naturally come in contact with the
plans should be firmly pinned to the plan/building board with T-Pins. Take a look at the photos in these instructions of the
wing construction and you will see what we mean. In the pictures you will see that lots of T
-Pins have been used to anchor
the parts firmly in position on the plans.

.
WING PANEL CONSTRUCTION
The KADET LT-40’s wing is designed to be built in two halves - called the LEFT WING PANEL and the RIGHT WING PANEL
(see full-size Plan Sheet 2). Each wing panel should be built directly on top of its own plan, using the plan as a pattern to
position the parts. It’s best to work on just one wing panel at a time. Occasionally you will find as you are working on one wing
panel that the parts you have already installed will be covering up some of the plan lines and text that you are looking for in a
subsequent step. In that case, simply refer to the other wing panel plan (the one you are not using) to see what is covered up.
Let
’
s get started by building the LEFT WING PANEL first!
REMEMBER:
These instructions are written assuming the use of MEDIUM CA glue for all steps, unless otherwise noted. In other
words, if an instruction simply says "glue" part A to part B - use MEDIUM CA!
1. Cut the drawing of the LEFT WING PANEL loose from the rest of Plan Sheet 2.
Tape or pin it on top of your building board. Then cover the plan with a sheet of
wax paper, also taped down. This will keep excess glue from sticking to the plan
when you are gluing the parts in place.
2. Locate two 1/4"x1/2"x36" hardwood pieces for the Main Wing Spars and two
1/4"x1/2"x10-1/8" balsa pieces for the Spar Doublers (see the wing cross-section
drawings on Plan Sheet 2 to understand the location of the Spar Doublers). Use
Slow CA to glue a Spar Doubler onto one end of each Main Wing Spar, making
sure that the sides of the pieces are flush with each other before the glue dries.
3. Pin one of the Main Wing Spar assemblies from the previous step in position on
the plan. This assembly will now be referred to as the Bottom Main Spar.
IMPORTANT: Position the Bottom Main Spar on the plan precisely by lining up the
inboard end of the Spar Doubler flush with the location of the first W5 wing rib
(look for note on plan that says "1/4"x1/2" BALSA SPAR DOUBLERS END
HERE).
4. Use a razor saw to cut off the excess tip end of the Bottom Main Spar flush with the outside edge of the last W5 wing rib
(see note on plan, "BOTTOM SPAR ENDS HERE").
5. Pin die-cut balsa wing sheeting piece WS-B2 in place on the plan, gluing its front edge to the back of the Bottom Main Spar
at the same time.
6. Locate one 1/4"x3/8"x36" balsa stick for use as the Bottom Rear Spar and pin it in place on the plan, gluing it to the rear
edge of WS-B2 at the same time. Cut off the tip end of the Bottom Rear Spar flush with the outside edge of the last W5
wing rib (see note on plan, "BOTTOM SPAR ENDS HERE").
7. Pin die-cut balsa wing sheeting piece WS-B3 in place on the plan, gluing its front edge to the back of the Bottom Rear Spar
at the same time.

.
8. Pin the pre-shaped balsa Trailing Edge in place on the plan, gluing it to the back edge of WS-B3 at the same time. Be sure
to align all of the notches in the Trailing Edge with the wing rib locations on the plan.
NOTE: It is possible for plan paper to shrink or expand slightly with humidity
changes. If it has, this is where you will notice it! You may find that the rib
notches in the Trailing Edge do not exactly match the rib locations on the plan.
Nonetheless, they should be very close, not off by more than the thickness of a
rib. A slight difference is nothing to worry about! The machine-cut notches in the
Trailing Edge are correct, and you should build your wing according to them. To
install a wing rib in the steps coming up, simply put the rear end of the rib in the
notch, and then align the rest of the rib parallel with the rib lines on the plan. Do
not alter the notches in the Trailing Edge!
9. Carefully remove all the wing ribs (W1 through W5) from die-cut sheets #1, #2,
and #3. Take time to familiarize yourself with the ribs and how they differ. You will
notice that ribs W1, W2, W3, and the front of rib W4 are smaller than the W5 ribs
to all allow for the 3/32" thick balsa wing sheeting pieces. There are also some
differences between the size of the spar cutouts in each rib.
10. Glue wing ribs W2 and W3 in place. They should be glued to the Bottom Main
Spar, the Bottom Rear Spar, the WS-B2 and WS-B3 wing sheeting, and the
Trailing Edge. Make sure the ribs are sitting up straight, perpendicular to the
building board before the glue dries.
11. Glue one SW-2 Shear Web in place on top of the Bottom Main Spar, and up tight against rib W3.
12.
Glue one SW
-
3 Shear Web in place on top of the Bottom Rear Spar, and up tight against rib W3.
13. Glue rib W4 in place, gluing it to the Bottom Main Spar, the Bottom Rear Spar, the Trailing Edge, and to the ends of Shear
Webs SW
-
2 and SW
-
3.
14. Glue another SW-2 Shear Web to the Bottom Main Spar and another SW-3 Shear Web to the Bottom Rear Spar, also
gluing them against rib W4.
15. Next glue the first W5 rib in place, followed by a SW-1 Shear Web on the Bottom Main Spar and a SW-3 Shear Web on the
Bottom Rear Spar. Continue this procedure of gluing in a rib, followed by the adjoining Shear Webs, until all the remaining
W5 ribs and Shear Webs are glued in place.
NOTE: There are no SW-1 Shear Webs called for in the last two rib bays nearest the wing tip, nor any SW-
3 Shear Webs in
the last three rib bays nearest the wing tip.
16. Now trial fit the other Main Wing Spar assembly (that you made back in step 2) in place in the top front notches in the wing
ribs. This is now referred to as the Top Main Spar. Make sure that the end of the balsa Spar Doubler lines up flush with the
side of the first W5 wing rib. When satisfied with the fit, glue the Top Main Spar assembly permanently to all the wing ribs.
17. Locate a 1/4"x3/8"x36" balsa stick for the Top Rear Spar and glue it in place in the top rear notches in the wing ribs.
NOTE: The tip end of the Top Rear Spar is also extra long. Do not cut it off at this time - we will do that later, after the wing
tip is installed.

.
18.
Glue the pre
-
shaped balsa Leading Edge in place in the notches in the front of the wing ribs.
CAUTION: Take a close look at the end of the Leading Edge before gluing it in place! Notice that it is not
symmetrical! Hold the Leading Edge against one of the wing cross-section drawings on Plan Sheet 2, and after you
are sure that you have it matched up correctly, mark an "up" arrow on one end. Then make sure you glue it into the
wing right side up!
NOTE:
By the way, you’ve probably already noticed that the tip end of the Leading Edge is also too long, just like the Top Main
Spar & Rear Spar! Guess what? Do not cut the Leading Edge off at this time - we will do that later, after the wing tip is
installed.
19. Remove part DRG (dihedral root gauge) from die-cut lite-ply sheet #11. Match it up to the full-size pattern (left) and mark
the correct edges as indicated
-
TOP, BOTTOM, DIHEDRAL ANGLE, and RIB W2.
20. Hold DRG up against the Top & Bottom Main Spars, with the bottom edge of the
gauge down tight against the wing sheeting and the "RIB W2" edge up tight
against rib W2. Use a pencil to draw along the "DIHEDRAL ANGLE" edge onto
the Top & Bottom Main Spars. Next mark the Top & Bottom Rear Spars in the
same manner. These lines represent where the outside face of rib W1 will be
installed.
21. Carefully slide wing rib W1 into position in the root end of the wing panel. Notice
that W1 should not be installed straight up and down like all the rest of the wing
ribs, but rather it must have its top tilted slightly towards the wing tip to provide the
finished wing with the proper amount of dihedral angle (see Wing Front View on
Plan Sheet 2). Before you glue W1 to any of the wing structure, eyeball it from
several different angles to verify that it is in the correct position. Use DRG and the
line up marks you put on the spars in the last step, as guides for getting the tilt of
W1 exactly right. To double check the alignment, look straight down on the W1 rib
from directly above to make sure its bottom edge is properly aligned with the edge
of the wing sheeting. If it is, go ahead and tack glue the bottom of W1 to the wing
sheeting with a couple small drops of Thin CA glue. Next, use DRG in the manner
shown here (notice it’s upside down compared to step 20) to keep W1 tilted at the
proper angle while you glue it to the Top Spars, the Leading Edge, and the
Trailing Edge with Thin CA. After W1 is secured into correct position, go back and
re-glue the entire bottom of the rib to the wing sheeting.
22. Once all the glue joints are dry, you can unpin the Left Wing Panel from the
building board!
23. Now we can add the wing tip! The only way to get the die-cut lite-ply WTP (wing
tip plate) in place is to slide it over the ends of the Top Spars, Leading Edge, and
Trailing Edge - all at the same time.
It’s a little tedious, but with a bit of careful wiggling and pushing, you should be
able to get it to slide on OK.

.
24.
Once in position, securely glue WTP to all the other parts it comes in contact with.
NOTE: Practically everywhere that WTP
comes in contact with another part there
are angles involved. This means there
will naturally be some unavoidable small
gaps between the parts. For instance,
underneath both of the Top Spars there
will be a gap. Also, around the backside
of the Leading Edge there will be some
gaps. All of these gaps can be filled with
light-weight wood filler later on during
preparation for covering.
25. Cut off the Leading Edge, Trailing Edge, Top Main Spar, and Top Rear Spar flush with the flat bottom surface of WTP.
NOTE: It’s best to first make a "pretty close" cut with a razor saw to quickly remove the bulk of the part, and then use a
sanding block to get everything perfectly flat and flush.
26. Glue die-cut balsa wing sheeting piece WS-T3 in place on the top of the wing, between the Top Rear Spar and the Trailing
Edge.
27. Glue die-cut balsa wing sheeting piece WS-B1 in place on the bottom of the wing, between the Bottom Main Spar and the
Leading Edge.
NOTE: There will be a wedge-shaped gap where WS-B1meets the Leading Edge. This is normal! Simply run a bead of
Slow CA in the gap and let it dry - this will secure WS-B1 to the Leading Edge. Fill the rest of the gap with light-
weight wood
filler before covering.
28. Carefully saw off, and then block sand, the root ends of the Spars, Leading Edge, and Trailing Edge flush with the pre-
angled W1 wing rib. Use a large sanding block and sand slowly to keep the end of the wing panel straight and true. Try not
to sand into W1.
29. Look closely at rib W1 and you’ll see that a cutout for the aileron servo has been partially pre-cut in the rib - it’s a large
inverted "U" shape, located aft of the main spars. Also notice that the vertical legs of the cutout stop 1/4" from the bottom of
the rib. In this step, you will complete the aileron servo cutout in rib W1! First lay the wing panel flat on the workbench and
use a modeling knife to cut straight down through the last 1/4" of rib on both vertical legs. Stop cutting when you get to the
bottom wing sheeting. Then carefully break out the portion of the rib inside the cutout area.
The LEFT WING PANEL is now complete!
Repeat Steps 1 through 29 to build the RIGHT WING PANEL!

.
JOINING THE WING PANELS
30. The first thing you need to do is check the fit of the two wing panels to each other
- WITHOUT GLUE! Start by locating die-cut lite-ply part DTG (dihedral tip gauge)
and pinning it to the underside of the last W5 rib (nearest the wing tip) in the Left
Wing Panel. The notches in the DTG should straddle both bottom wing spars.
31. Lay the Right Wing Panel on a large flat surface, such as a big table or on the
floor. Mate the root end of the Left Wing Panel up against the root end of the
Right Wing Panel. The DTG (pinned to the wing tip of the Left Wing Panel) will set
the proper dihedral angle by holding the left wing tip up 3-3/4" off the table (see
halfsize Wing Front View on Plan Sheet 2). Make sure the leading and trailing
edges of both wing panels are perfectly aligned with each other so that there is no
twist between the panels. Look for gaps between the W1 root ribs. If you installed
both W1 ribs at the correct angle, and you sanded all the spars, etc. perfectly
flush with the W1 ribs, then you should not have any significant gaps. A small gap
of 1/16" or less is insignificant and will be OK. If you have a larger gap, you will
have to figure out how it happened and correct it before going on to the next step.
32. Locate the two laser-cut plywood MADB (main dihedral braces). Using the full-
size pattern of MADB as a guide, mark a center-line on the front and back of both
braces.
33.
Use a modeling knife or razor saw to cut
out the portions of the W1 root rib where
the MADBs will go. Do this to the W1 rib
in both wing panels. TIP: Use a pencil
and straight edge to mark guidelines on
the rib before cutting. Make repeated
short shallow cuts until you get all the
way through the wood, whether you are
using a knife or saw. This will help avoid
splintering the rib!

.
34.
Carefully slide both MADBs into position in the Right Wing Panel. Push them in slowly, being careful not to snag and break
the W1 or W2 ribs. Position both MADBs carefully before gluing them to the spars.
Check:
1. that the MADBs are tight against the front and back of the Top & Bottom Main Spars;
2. that the MADBs are exactly halfway in the Left Wing Panel - the center lines you drew on the MADBs should line up
with the outside face of W1;
3. that the bottom edges of the MADBs are down tight against the bottom wing sheeting;
4. that the exposed ends of the MADBs line up with each other from the front view. When all of these checks are OK,
glue the MADBs to the main spars with Thin CA glue. Mop up any excess Thin CA with a rag. Let dry.
35. WITHOUT GLUE, slide the Left Wing
Panel onto the exposed ends of the
MADBs, again being careful not to
break the W1 or W2 ribs. Once again
set-up the entire wing assembly on a
large flat surface with the Right Wing
Panel flat on the table and the Left Wing
Panel propped up by the gauge DTG -
just as you did in step 31.
(If the MADBs are preventing the wing panels from fitting like they did before, trim or sand the MADBs where necessary to
eliminate the problem.)
Make sure the opposing Leading and Trailing Edges are lined up with each other so there is no twist between the wing
panels. Use plenty of pins to hold the wing panels tightly together in correct alignment. Once everything looks good, use
Thin CA to glue the MADBs to the main spars in the Left Wing Panel. Do not apply glue anywhere else yet! When dry, you
should be able to pick up the entire wing assembly without fear of the wing panels shifting. The glued MADBs and the pins
should hold everything together adequately for the next step.
36. Pick up the wing assembly, turn it over, and put a strip of masking tape along the entire center joint on the bottom of the
wing. Now turn it back over and flow Thin CA glue into the center joint from the top. Run the glue in along the entire length
of the W1 ribs. Use just enough glue to flood the entire joint, but not so much that it runs all over the place. The masking
tape should keep the glue from running out the bottom. Have a rag handy to mop up any excess glue. If you have some
gaps that the Thin CA won’t fill in, switch to Medium CA or Slow CA to fill them. Let dry! Then remove the masking tape
and all the pins.
37. Before you can put on the rest of the
top wing sheeting, you must go back
and re-glue ALL the joints that will be
inside the sheeted area. Make sure
there is a visible, but small, fillet of glue
in every joint. Don’t let any excess glue
get on top of the ribs, or along the
spars, where the WS-T1 and WS-T2
wing sheeting pieces will go.
38.
Glue the two WS
-
T2 die
-
cut balsa wing sheeting pieces in place between the top rear spars and the top main spars.
39.
Glue the two WS
-
T1 die
-
cut balsa wing sheeting pieces in place between the top main spars and the leading edges.
40. Now go back and re-glue every joint in the wing with Medium CA or Slow CA glue! Make sure there is a visible, but small,
fillet of glue in every joint. Take your time and don’t miss any joints! Each and every one of them contributes to the finished
strength of the wing.
AILERON INSTALLATION
41. Locate the two pre-shaped balsa Center Section Trailing Edge pieces. They are identical to each other at this point, but by
the time you finish the next step they won’t be - so mark LEFT (BOTTOM) on one piece and RIGHT (BOTTOM) on the
other.

.
42.
On the LEFT (BOTTOM) Center Section Trailing Edge piece, draw a box 1/4" wide x1/2" deep, exactly 7/16" from the end.
43.
Continue the lines down the front of the piece, until you reach the bottom of the pre
-
cut groove in the front.
44. Using a razor saw, carefully cut along the side lines of the box, stopping when the blade is deep enough to reach across to
both end lines.
45. Use a modeling knife to "chip" the wood out between the saw cuts until you have a notch the full depth of the box you drew
originally.
46.
Repeat steps 42 through 45 to make the RIGHT (BOTTOM) Center Section Trailing Edge a mirror image of the Left one.
47. Familiarize yourself with the pre-bent Aileron Torque Rods w/Brass Bearings. Note that there is a Left and a Right Torque
Rod. Study their positions on the full-size plans to help you identify which one is Left and which is Right. Notice that when
the Torque Rods are in position in the wing, the threaded end of the torque rod will come out the bottom of the wing and the
shorter unthreaded end will face back into the aileron.
NOTE: The threaded portion of the Torque Rods should lean back slightly towards the rear of the airplane when the
ailerons are in neutral position. That rearward lean provides the KADET LT-40 with a small amount of "differential"
movement in the ailerons (more up than down), which makes for smoother turning.
48. Use a small amount of Slow CA to glue the Brass Bearing portion of the Left
Aileron Torque Rod into the groove in the front of the Left Center Section Trailing
Edge piece. GLUE ONLY THE BRASS BEARING, NOT THE WIRE PORTION OF
THE TORQUE ROD! The wire portion of the Torque Rod must be completely free
to rotate inside the Brass Bearing.
TIP: It’s not necessary to apply glue along the full length of the Brass Bearing.
Keep all glue 1/8" away from the ends of the Brass Bearing to minimize any
chance of glue seeping inside the bearing and causing a bind in the
movement of the Torque Rod.
49.
Repeat step 48 to glue the Right Aileron Torque Rod into the groove in the front of the Right Center Section Trailing Edge.
50.
Apply a bead of Slow CA to the leading edges of the Left Center Section Trailing Edge piece. Keep the glue on the balsa
-
do not get any glue on the Torque Rod or the Brass Bearing! Hold the Center Section Trailing Edge assembly in position on
the trailing edge of the wing until the glue dries. Use a straight edge to confirm that the bottom surface of the part is flush
with the bottom surface of the wing. Let dry.

.
51. Repeat step 50 to glue the Right Center
Section Trailing Edge in place on the
back of the wing, also gluing it to the Left
Center Section Trailing Edge at the
same time.
52. Double check to verify that both Aileron
Torque Rods will pivot freely. If they
don’t, you must find the problem and
correct it now, before going on to the
next step.
53. Locate the two pre-shaped balsa wood Ailerons. Using a 3/32" dia. drill bit, drill a hole in one end of each aileron to accept
the Aileron Torque Rod wire. The location of the hole must be centered on the leading edge of the aileron, and it should be
1-3/8" from the end of the aileron. The path of the hole must travel straight into the core of the aileron, centered equal
distance from both sides. The hole should be 5/8" deep.
54. Use a modeling knife to cut a (3/32" wide x3/32" deep) groove in the leading edge of each aileron to accept the Aileron
Torque Rod wire. The groove should go from the 3/32" hole you drilled in the last step to the root end of the aileron. Trial fit
(without glue) the aileron over the end of the Torque Rod wire to check the fit.
55. Mark the locations for the Sig Easy
Hinges (4 per aileron) on the leading
edge of the ailerons and on the trailing
edge of the wing.
56. Cut slots for the hinges in the Ailerons
and Wing following the instructions
"INSTALLING SIG EASY HINGES" at
the end of this wing construction section
(perform steps 1 and 2).
57. Once all the slots have been cut, insert a single Easy Hinge halfway into each slot in the trailing edge of the wing. DO NOT
GLUE THE HINGES IN AT THIS TIME!
58. Now carefully slide the ailerons onto the exposed half of the Easy Hinges, and onto the exposed arm of the Torque Rod, all
at the same time. You will find it easiest to slide the ailerons onto the hinges at angle, one hinge at a time, starting from the
tip end, instead of trying to push it straight onto all the hinges at once. ONCE AGAIN, DO NOT GLUE THE HINGES IN AT
THIS TIME!
59. Tape the ailerons into neutral position, with the root end in perfect alignment with the fixed Center Section Trailing Edge
pieces.
60. Pin a piece of scrap balsa or plywood to the bottom surfaces of both the aileron and the wing, out near the wing tip, to hold
this end of the aileron securely in neutral position.
61. Razor saw and block sand the end of the aileron to match the shape of the wing tip. Here are a couple different views
showing the proper final shape of the wing tip/aileron tip area.

.
62.
Remove the ailerons and hinges from the wing and set them aside until "COVERING THE KADET LT
-
40" .
COMPLETING THE WING
63. Use a sanding block with fresh 80 grit
sandpaper to give the entire wing a final
sanding. Sand just enough to take off
any prominent high spots and to smooth
out any mismatched joints between
parts.
Be sure to block sand all the WS-*
wing sheeting pieces down flush with the spars, leading edges, and trailing edges. Avoid
sanding into the spars, leading edges, and trailing edges themselves as much as possible - just sand the wing sheeting
pieces down to them! If you’ve got sheeting that is lower than the spars, etc., then fill in the low spot with light-weight wood
filler and sand that smooth.
You shouldn’t have to sand the edges of the wing ribs at all - they should already be level with the surface of the spars, etc.
However, you may need to use a small sanding block to touch up any excess glue on the rib-to-spar joints, the rib-to-
leading edge joints, and the rib-to-trailing edge joints. Excessive sanding of the ribs themselves may distort the airfoil
shape.
64. Make an opening (1" wide x2" long) in the bottom wing sheeting for the aileron servo. Mark and cut out the opening
according to the dimensions shown here:
 Front edge of the cutout = 1/2" aft of the main spar.

Rear edge of the cutout = 2
-
1/2" aft of the main spar.
65. Remove part ASM aileron servo mount from die-cut plywood sheet #14. Use Slow CA to glue ASM in place on the bottom
of the wing. Make sure the cutout in the middle of ASM is centered over the opening in the bottom wing sheeting. Use
enough glue to fill in the gap under each side of ASM, caused by the dihedral angle.
66.
Glue both 1/16"x1"x3
-
5/16" plywood Trailing Edge Stiffeners in position along the top trailing edge of the wing.

.
REINFORCE WING CENTER JOINT
67.
A 1" wide x 24" long piece of fiberglass cloth tape is supplied to reinforce the joint between the Right & Left Wing Panels.
Cut the 24" long tape into one 18" long piece and one 6" long piece.
68. Lay the 18" long piece of fiberglass tape over the center joint on top of the wing. Using a small amount of Thin CA, tack
glue the end of the tape to the balsa Center Section Trailing Edge, right in front of the 1/16" plywood Trailing Edge
Stiffeners. Make sure the width of the tape is overlapping 1/2" onto the Right Wing Panel and 1/2" onto the Left Wing
Panel.
69.
After the Thin CA dries, pull the other end of the tape completely around the Leading Edge and down onto the bottom
surface of the wing. The tape should lay nice and flat, tight against the top surface of the wing. Again make sure the tape is
centered over the joint - half on the Right Wing Panel and half on the Left Wing Panel. Then tack glue the tape to the
Leading Edge.
70. Now carefully flow Thin CA glue onto the tape on top of the wing. Use just enough glue to saturate the tape - too much
glue will run outside the tape and get all over the place. If you do get too much glue on the tape, take a clean rag and
quickly wipe off the excess before it dries (don’t rub too hard and disturb the positioning of the tape). By working slowly
and gluing small (3" long) sections of tape at a time, you should be able to glue the entire length of tape in place without
any major wrinkles or bumps.
CAUTION: Do the gluing in a well ventilated area to avoid breathing the fumes from the Thin CA glue!
71.
After you
’ve finished gluing the fiberglass tape on the top of the wing, turn the wing over and glue the remainder of the
original 18" long piece to the bottom front of the wing. Cut it off right in front of the plywood ASM part.
72. Using the same techniques, glue the 6" long piece of fiberglass tape to the
bottom of the wing. It goes from the back of plywood part ASM, all the way off the
end of the wing. When dry, cut it off flush with the end of the wing.
NOTE: Be very careful when gluing the tape in the area of the Torque Rods! If
you get too much Thin CA in that area, the excess could seep into the Torque
Rods, binding them up permanently.
73.
After all the glue is dry, lightly sand the fiberglass cloth with a piece of 220 grit
sandpaper to remove any lumps or high spots. Be careful not to sand through the
fiberglass cloth.
The basic wing construction is now complete! Set the wing aside until "COVERING THE KADET LT
-
40"
INSTALLING SIG EASY HINGES
WARNING:
SIG EASY HINGES are designed to be used in conjunction with Thin CA glue. Thin CA (any brand) is
the ONLY type of glue that can be used on EASY HINGES - do not use epoxy or any other type of
glue on EASY HINGES!
Each ultra-thin EASY HINGE is actually a 3-part laminate - a tough plastic inner core sandwiched between 2 layers of
absorbent wicking material. They have been chemically treated to slow down the drying time of Thin CA (which is normally
instant), to allow the glue time to soak all the way to the ends of the hinge and into the wood surrounding it. Once the glue
has dried, the hinge cannot be pulled from the structure without tearing wood out with it.
1. Begin by carefully cutting a very shallow slit at the hinge location using a fresh, sharp #11 blade in your modeling knife.
This first slit should be very shallow so you can better control the direction of the knife. It's main purpose is to establish
your hinge slot in the right place, so concentrate on staying on the hinge line and don't try to cut too deep.
NOTE: Make the slit slightly wider than the actual hinge.

.
2. Now make 3 or 4 more cuts in the exact same line, going slightly deeper each
time. As you make these additional cuts, concentrate on staying in the slit and
keeping the blade headed straight into the center of the wood so that it won’t
come out the side of the part. You will find that as the blade gets deeper into the
wood, it will become harder to move it along the slot. Try "wiggling" the knife
handle in the slot to make it cut, instead of trying to "slice" the blade along in one
continuous motion. Continue making additional cuts until the slot is
approximately 1/2" deep.
CAUTION: You must use extreme care to avoid cutting yourself while cutting the hinge slots. If the balsa wood breaks
while you are pushing on the knife, the blade could go into your hand before you can stop it. A good precaution is to wear
a leather glove on the hand that is holding the model part while you are cutting the slots.
3.
After all the slots have been cut, insert a single Easy Hinge halfway into each hinge slot in the stabilizer (or fin, or wing, as
the case may be). If the hinge is difficult to push in, re-insert the knife and move it back and forth in the slot a few more
times and then try again. DO NOT GLUE THE HINGES IN AT THIS TIME!
4. Now carefully slide the elevator (or rudder, or aileron) onto the exposed half of
the Easy Hinges. You will find it easiest to slide the part onto the hinges at angle,
one hinge at a time, instead of trying to push it straight onto all the hinges at
once. Don’t be overly concerned if the hinges don’t end up perfectly straight or
centered in the slots - they do not have a center line.
ONCE AGAIN, DO NOT GLUE THE HINGES IN AT THIS TIME!
5. To set the proper amount of gap between the model parts, simply deflect the control surface to the maximum amount of
travel needed. This will automatically set the proper hinge gap! Keep in mind that for best control response the gap should
be kept as small as possible, but big enough to allow full movement of the control surface. If everything appears to function
properly, remove the parts and take the hinges out of the slots. Set everything aside until after the model has been
covered.
THE MODEL PARTS SHOULD BE COMPLETELY COVERED BEFORE PROCEEDING TO THE NEXT STEP!
6.
After the model parts have been covered, use the X
-Acto knife to re-open the
hinge slots by cutting through the covering that went over them. Re-install the
hinges and re-adjust the hinge gap.
7.
Place three or four drops of Thin CA glue directly onto the Easy Hinge in the gap.
You will notice that the glue is quickly wicked into the slot as it penetrates both
the wood and the hinge. Turn the part over and glue the other side of the Easy
Hinge. Continue this process until you have glued both sides of all the Easy
Hinges! Keep a rag handy to wipe off any excess Thin CA. (CA glue residue can
be cleaned from most iron-on plastic covering materials with CA Debonder).
VERY IMPORTANT: Make only one application of glue to each side of an Easy Hinge! If you apply additional glue to the
hinge after the first application of glue is already dry, the second application of glue will merely puddle in the hinge gap and
make the hinge too stiff to operate properly. The excess glue could also weaken the hinge! When properly glued, the
portion of the Easy Hinge that you can see in the hinge gap should have a dry appearance, not wet. A dry appearance
indicates that almost all of the glue has properly soaked into the hinge slot. A wet appearance indicates that excess glue is
puddled in the hinge gap. Three to four good size drops of Thin CA should be about the right amount.
NEVER USE CA ACCELERATOR ON EASY HINGES!
8. Let the glue dry a minimum of 3-5 minutes before flexing the hinges. At first you might notice a little stiffness in the joint.
This will go away after the hinges have been flexed back and forth a couple dozen times.

.
FUSELAGE CONSTRUCTION
74. Use a sanding block to very lightly sand the edges of all the die-cut plywood
fuselage parts to remove any burrs or rough spots. Hold the sanding block at a 90
angle to the part while doing this. Remember, sand very lightly! You only want to
smooth the edges of the parts, not change their size or shape.
75. Fuselage formers F1, F2, F3, and F6 are laser-cut plywood, and they do not have
their part name/number pre-printed on them. Use a pencil to mark each of these
formers with their proper name/number. Also mark TOP and FRONT on formers
F1, F2, and F3, after making sure that the holes in those three formers are
oriented EXACTLY as shown.
76. The group of four holes located at the bottom center of former F1 are for the mounting of the Nose Gear Bearing. Turn F1
over, and use a hammer to gently tap a 4-40 Blind Nut into each of those four holes from the backside. Tap the Blind Nuts
in until the flange is flush against the back surface of F1. Apply a little Medium CA around the flanges of the Blind Nuts to
keep them from coming loose. Be careful not to get any glue in the threads of the Blind Nuts.
77. Trial mount the nylon Nose Gear Bearing to the front of F1 using the four 4-40 x1/2" Mounting Bolts provided. Then remove
the Nose Gear Bearing and the four Mounting Bolts and store them away until needed later.
78.
Draw a vertical center line on the front of
F1, exactly equal distance from each
side. Then set your engine on the front
of F1 as shown in the photo, with the
crankshaft of the engine directly in line
with the vertical center line. Finally,
make two pencil marks on F1, one on
each side of the engine’s crankcase, to
indicate where the inside of the two
Engine Mounts should be.
79. Draw a vertical line through both of the pencil marks you made in the previous
step. Make sure that both lines are exactly parallel to the vertical center line.
80. Bolt the Engine Mounts onto the front of F1 as shown, using the four 6-32 x3/4"
Mounting Bolts and the four 6-32 Blind Nuts provided.
NOTES:
The holes in F1 for the bolts are oblong, to allow the Engine Mounts to be shifted
sideways to accommodate engines with different width crankcases. Thus, we can't
just hammer the Blind Nuts in as we did for the Nose Gear Bearing. Instead, first
assemble the Mounts, Bolts, and Blind Nuts loosely in place on F1.
Then as you begin to tighten down the Bolts and Blind Nuts for the first time, line up the inner sides of the Mounts with the
two lines that you drew in the last step. Continue tightening down the Mounting Bolts until the prongs of the Blind Nuts start
to get a grip on the back of F1. Double check that the sides of the Mounts are still lined up with the lines, and then continue
tightening the Bolts. Keep tightening the Bolts until the prongs of the Blind Nuts are drawn all the way into the wood, with
the flange flush against the back of F1.