Sportsman Aviation F-20 TIGERSHARK 40 User manual

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Specifications:
●Wing Span: 47 Inches
●Wing Area: 535 Square Inches
●Length: 54 Inches
●Weight RTF: 5.5 - 6.5 Pounds
●Wing Loading: 23.6 - 28 Ounces Per Square Foot
●Functions: Ailerons, Elevator, Rudder & Throttle
●Engine Required: .40 - .53 Two-Stroke
●Radio Required: 4Ch or More w/4 Standard Servos
INSTRUCTIONS FOR FINAL ASSEMBLY
The Sportsman Aviation F-20 Tigershark 40 ARF is distributed
exclusively by Global Hobby Distributors
18480 Bandilier Circle, Fountain Valley, CA 92708
All contents copyright © 2004, Global Hobby
Distributors Version V1.0 February 2004
Kit Product Number 127520
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦The Sportsman Aviation F-20 Tigershark 40 ARF is not intended for inexperienced pilots. It is in no
way a trainer. If you are not comfortable flying fast sport aircraft, we strongly suggest returning the F-20 Tigershark 40 ARF
(brand new, in the box with all original packaging and your dated sales receipt) to the place of purchase.

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TABLE OF CONTENTS
This R/C airplane is not a toy! If misused or abused, it can cause serious bodily injury and/or damage to property. Fly only
in open areas and preferably at a dedicated R/C flying site. We suggest having a qualified instructor carefully inspect your
airplane before its first flight. Please carefully read and follow all instructions included with this airplane, your radio control
system and any other components purchased separately.
OUR GUARANTEE
Sportsman Aviation guarantees this kit to be free from defects in both material and workmanship at the date of purchase. This does not cover any
component parts damaged by use, misuse or modification. In no case shall Sportsman Aviation's liability exceed the original cost of the
purchased kit.
In that Sportsman Aviation has no control over the final assembly or material used for final assembly, no liability shall be assumed for any damage
resulting from the use by the user of the final user-assembled product. By the act of using the final user-assembled product, the user accepts all
resulting liability.
FOR YOUR INFORMATION
To make your modeling experience totally enjoyable, we recommend that you get experienced, knowledgeable help with assembly and
during your first flights. Your local hobby shop has information about flying clubs in your area whose membership includes qualified
instructors. If there is no hobby shop in your area, we recommend that you contact the AMA at the address below. They will be able to
help you locate a flying field near you.
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie IN 47302-9252
[phone]
www.modelaircraft.org
SAFETY WARNING
Safety Warning ........................................................................... 2
Introduction ................................................................................. 3
Section 1: Our Recommendations ............................................ 4
Section 2: Tools and Supplies Required .................................. 5
Section 3: Kit Contents ............................................................. 5
Section 4: Replacement Parts .................................................. 7
Section 5: A Note About Covering ............................................ 7
Section 6: Wing Assembly ........................................................ 8
Section 7: Wing Fairing Installation ........................................ 10
Section 8: Stabilizer Installation .............................................. 13
Section 9: Control Surface Hinging ........................................ 18
Section 10: Landing Gear Installation .................................... 21
Section 11: Engine Installation ............................................... 24
Section 12: Fuel Tank Assembly & Installation ...................... 25
Section 13: Throttle Control System Installation .................... 27
Section 14: Rudder Control System Installation .................... 29
Section 15: Elevator Control System Installation ................... 31
Section 16: Aileron Control System Installation ..................... 33
Section 17: Cowling Installation .............................................. 35
Section 18: Final Assembly ..................................................... 37
Section 19: Balancing the F-20 Tigershark 40 ARF 39
Section 20: Control Throws ..................................................... 40
Section 21: Preflight Check & Safety ..................................... 40
Full-Size Elevator Pushrod Assembly Template ..................... 42
Product Evaluation Sheet ........................................................ 43

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Thank you for purchasing the Sportsman Aviation F-20 Tigershark 40 ARF. Before completing the final assembly
of your new airplane, please carefully read through this instruction manual in its entirety. Doing so will ensure
your success the first time around!
MODELTECH F-20 TIGERSHARK 40 ARF FEATURES
●Pre-Built from High-Quality Balsa, Light Plywood and Foam
●Pre-Covered with Real Iron-On, Heat-Shrink Covering Material
●Sleek, Fast and Agile Design
●All Control Horns and Pushrods Enclosed Inside the Airframe for Less Drag
●Durable Steel Main Landing Gear and Nose Gear Strut
●Includes Most Hardware - Wheels, Fuel Tank, Pushrods, Engine Mount, Etc.
●Fast and Easy Assembly - Over 60 High-Resolution Digital Photos and Drawings to Guide You
This instruction manual is designed to guide you through the entire assembly process of your new airplane in the least
amount of time possible. Along the way you'll learn how to properly assemble your new airplane and also learn tips that
will help you in the future. We have listed some of our recommendations below. Please read through them before
beginning assembly.
●Please read through each step before beginning
assembly. You should find the layout very complete and
straightforward. Our goal is to guide you through
assembly without any of the headaches and hassles
that you might expect.
●There are check boxes next to each procedure. After
you complete a procedure, check off the box. This will
help prevent you from losing your place.
●Cover your work table with brown paper or a soft cloth,
both to protect the table and to protect the parts.
●Keep a couple of small bowls or jars handy to put the
small parts in after you open the accessory bags.
●We're all excited to get a new airplane in the air, but take
your time. This will ensure you build a straight, strong and
great flying airplane.
●If you come across this symbol ☞, it means that this is
an important point or an assembly hint.
If you should find a part missing or damaged, or have any questions about assembly,
please contact us at the address below:
Global Services
18480 Bandilier Circle
Fountain Valley CA 92708
Phone: [phone] Fax: [phone] Email: [e-mail]
To enable us to better serve your needs, please include your email address with any correspondence you send to us.
Your email address will be added to our Customer Service Database so you will automatically receive free updates and
tech notices for your particular product. You will also receive repair status updates (if applicable) and other important
information about your product as it becomes available.
IMPORTANT INFORMATION ABOUT YOUR EMAIL ADDRESS
INTRODUCTION
CHECK IT OUT! We urge you to come check out our website at http://globalservices.globalhobby.com. There you will find public
message boards frequented by other Sportsman Aviation product owners and the Sportsman Aviation support staff. This is a great
place to learn about new Sportsman Aviation products, get help and suggestions for your current Sportsman Aviation products or
just simply hang out and chat with people that share your same interests.
Global Hobby Distributors will not disclose the information it collects to outside parties. Global Hobby Distributors does not sell,
trade, or rent your personal information to others . Your privacy is important to us.

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What Radio System and Servos Should I Use?
A standard four-channel radio control system with 3 standard ball bearing servos for the flight control surfaces and 1
standard servo for the throttle will be more than adequate. To get the most out of the airplane, we suggest using a radio
control system that features dual rates, and, depending on where you end up needing to mount your receiver and airborne
battery in the fuselage, you may also need several servo extensions.
SECTION 1: OUR RECOMMENDATIONS
This section describes our recommendations to help you in deciding which types of accessories to purchase for your new
Sportsman Aviation F-20 Tigershark 40 ARF. Please read through this entire section very carefully. We have
provided you with tips and recommendations that, if followed, will result in a great flying airplane. Failure to
follow our recommendations may result in a poor flying airplane.
What Engine Should I Use?
The F-20 Tigershark 40 ARF flies very well using a strong .40 - .46 size two-stroke engine. The airplane is light enough that
this size of engine will provide enough power for most fliers. It is on the low end of the recommended displacement range
though, so don't expect the airplane to be too blazingly fast. The engine is mounted on its side, so your engine's stock
muffler will work well.
For those flyers looking for a very fast airplane with a lot of power, we suggest using a .53 size two-stroke engine.
A .53 size two-stroke engine typically has the same footprint as a .40 - .46 size two-stroke engine, yet is lighter and more
powerful. This size engine will fit within the required engine mounting area and it won't require an after-market muffler.
With this engine, the airplane will be very fast and have a lot of extra power for great vertical performance.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦We don't recommend attempting to use a four-stroke engine in your F-20 Tigershark 40 ARF. The
forward profile of the airplane is very small and therefore will not accommodate the larger physical size of a four-stroke
engine. The airplane is designed specifically around .40 - .53 size two-stroke engines.
What Else Do I Need?
The F-20 Tigershark 40 ARF includes most of the hardware you'll need to finish the airplane. You will need to purchase
separately a spinner and some basic building materials, such as adhesives, protective foam rubber for your radio equipment,
and fuel tubing. We've provided a list below of the items we used on the airplane shown in this instruction manual.
Here's a List of What We Used to Finish Our F-20 Tigershark 40 ARF:
QTY. 1 210760 Magnum XLS .52A Two-Stroke Engine
QTY. 1 237152 Magnum 2" Chrome Spinner*
QTY. 1 608560 APC 11 x 6 Composite Propeller
QTY. 3 759349 Hitec HS-425 Ball Bearing Servos
QTY. 1 444104 Cirrus CS-36 Standard Servo
QTY. 1 115559 Thunderbolt # 3 Performance Glow Plug
QTY. 1 115923 Global XX Silicon Fuel Tubing
QTY. 1 868638 Dubro 1/4" Protective Foam Rubber
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦The part numbers listed for the Hitec servos are compatible with Hitec and JR radio control systems. These servos
are also available with connectors that are compatible with Futaba and Airtronics radio control systems. The part number listed for the
Cirrus standard servo is compatible with all name-brand radio control systems. This servo uses a universal connector.
*Spinner includes 1/4"- 28 crankshaft adapter.

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❑Kwik Bond Thin C/A # 887500
❑Kwik Bond Thick C/A # 887510
❑Kwik Bond 5 Minute Epoxy # 887560
❑Kwik Bond 30 Minute Epoxy # 887565
❑Kwik Bond C/A Debonder # 887545
❑Pacer Formula 560 Canopy Glue # 339176
❑Pacer Z-42 Blue Threadlocker # 339162
❑Lightweight Oil or Vaseline®
❑# 1 & # 2 Phillips Head Screwdrivers
❑1.5mm & 2.5mm Hex Wrenches
❑Adjustable Open-End Wrench
❑Wire Cutters
❑Needle Nose Pliers
❑Excel Modeling Knife # 692801
❑Scissors
❑Electric Drill
❑Assorted Drill Bits
❑Dubro T-Pins # 567685
❑Ernst Airplane Stand # 223977
❑Rotary Tool w/Cutting Disc & Sanding Drum
❑Ruler
❑Pencil
❑Builder's Triangle
❑220 Grit Sandpaper w/Sanding Block
❑Waxed Paper
❑Masking Tape
❑Paper Towels
❑Rubbing Alcohol
❑NHP Epoxy Mixing Sticks # 864204
❑NHP Epoxy Mixing Cups # 864205
SECTION 2: TOOLS AND SUPPLIES REQUIRED
The tools and supplies listed below will be necessary to finish the assembly of your F-20 Tigershark 40 ARF. We suggest
having these items on hand before beginning assembly.
We have organized the parts as they come out of the box for easier identification during assembly. Before you begin
assembly, group the parts as we list them below. This will ensure that you have all of the parts before you begin assembly
and it will also help you become familiar with each part.
Global Services
18480 Bandilier Circle
Fountain Valley CA 92708
Phone: [phone] Fax: [phone] Email: [e-mail]
On the Web
http://globalservices.globalhobby.com
If you find any parts missing or damaged, please contact us at:
SECTION 3: KIT CONTENTS
AIRFRAME ASSEMBLIES
❑(1) Fuselage w/Hatch Covers
❑(1) Right Wing Panel w/Aileron
❑(1) Left Wing Panel w/Aileron
❑(1) Horizontal Stabilizer w/Elevator Halves
❑(1) Vertical Stabilizer w/Rudder
❑(1) Prebent Steel Nose Gear Strut
❑(1) Nose Gear Wheel
❑(1) Nylon Steering Arm
❑(2) Nylon Spacers
❑(2) Wheel Collars
❑(3) M3 x 5mm Machine Screws
❑(1) 29" Pushrod Wire w/Z-Bend
❑(1) Adjustable Servo Connector Assembly
NOSE GEAR ASSEMBLY
THROTTLE CONTROL SYSTEM
❑(1) 34" Pushrod Wire w/Z-Bend
❑(1) Adjustable Servo Connector Assembly
Continued On Next Page
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KIT CONTENTS, CONTINUED....
MAIN LANDING GEAR ASSEMBLY
❑(2) Prebent Steel Main Landing Gear Wires
❑(2) Main Gear Wheels
❑(4) Nylon Landing Gear Straps
❑(2) Nylon Spacers
❑(2) Wheel Collars
❑(8) M3 x 12mm Wood Screws
❑(2) M3 x 5mm Machine Screws
❑(1) 8-1/2" Threaded Wire w/90º Bend
❑(1) 6-3/4" Threaded Wire w/Plain End
❑(2) 2-1/2" Prebent Torque Rods w/Flange Bearing
❑(2) Nylon Clevises
❑(1) Nylon 90º Snap Keeper
❑(2) Nylon Adjustable Control Horns (Small Thread)
❑(2) Wheel Collars
❑(2) M3 x 8mm Machine Screws
❑(4) C/A Style Hinges
ELEVATOR CONTROL SYSTEM
AILERON CONTROL SYSTEM
❑(2) 3-1/2" Threaded Wires w/90º Bend
❑(2) Nylon Clevises
❑(2) Nylon 90º Snap Keepers
❑(2) Nylon Adjustable Control Horns (Large Thread)
❑(2) Plywood Servo Tray Mounting Blocks (W26)
❑(1) Plywood Servo Tray (W18)
❑(6) C/A Style Hinges
RUDDER CONTROL SYSTEM
❑(1) 8-1/2" Threaded Wire w/90º Bend
❑(1) 2-1/4" Prebent Torque Rod w/Flange Bearing
❑(1) Nylon Clevis
❑(1) Nylon 90º Snap Keeper
❑(1) Nylon Adjustable Control Horn (Small Thread)
❑(3) C/A Style Hinges
❑(1) Engine Mount
❑(4) M3 x 18mm Socket-Cap Screws
❑(4) M3 x 30mm Socket-Cap Screws
❑(4) M3 Lock Nuts
❑(12) M3 Flat Washers
ENGINE MOUNT ASSEMBLY
❑(1) 320cc Fuel Tank
❑(1) Large Diameter Metal Plate
❑(1) Small Diameter Metal Plate
❑(1) Metal Neck-Reinforcement Ring
❑(1) Rubber Stopper
❑(1) Fuel Pick-Up "Clunk"
❑(1) M3 x 20mm Machine Screw
❑(1) Silicon Fuel Tubing
❑(2) Aluminum Tubing
FUEL TANK ASSEMBLY
MISCELLANEOUS FUSELAGE PARTS
❑(1) Fiberglass Cowling
❑(1) Clear Canopy
❑(3) M3 x 6mm Wood Screws
❑(9) M2 x 10mm Flange-Head Wood Screws
❑(1) Length of Clear Tubing
❑(1) Decal Set
❑(1) Plywood Wing Joiner (W17)
❑(1) Balsa Leading Edge Support (W20)
❑(2) Plywood Wing-Screw Doublers
❑(1) Balsa Wing Fairing (Front)
❑(1) Balsa Wing Fairing (Rear)
❑(2) M5 x 40mm Machine Screws
❑(2) M5 Flat Washers
MISCELLANEOUS WING PARTS
Don't forget that we stock a complete assortment of replacement parts. If for any reason
you should ever need to order replacement parts for your Sportsman Aviation F-20 Tigershark
40 ARF, don't hesitate to contact us. For your convenience, we have provided a
replacement parts list, along with the part numbers for easy ordering convenience, on the
next page. Contact your local Sportsman Aviation dealer for prices and availability.

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Global stocks a complete line of replacement parts for your Sportsman Aviation F-20 Tigershark 40 ARF. Listed below
are the replacement parts that are available along with their respective part numbers for easy ordering convenience. We
suggest ordering directly from your local dealer. If your dealer does not stock Sportsman Aviation products, you can order
directly from us at the address shown below:
Global Services
18480 Bandilier Circle
Fountain Valley CA 92708
Phone: [phone] Fax: [phone]
SECTION 4: REPLACEMENT PARTS
On the Web
http://globalservices.globalhobby.com
SECTION 5: A NOTE ABOUT COVERING
The covering material used on the Sportsman Aviation F-20 Tigershark 40 ARF is real iron-on, heat-shrink covering
material, not cheap "shelf paper." Because of this, it is possible with heat and humidity changes that the covering on
your airplane may wrinkle or sag. This trait is inherent in all types of heat-shrink material. To remove any wrinkles
that might be visible you will need to purchase, or borrow from a fellow modeler, a heat iron. If you need to purchase
one, the Global Heat Sealing Iron # 360900 is recommended.
Follow this simple procedure to remove the wrinkles:
❑Plug in and turn on the sealing iron to the medium-high temperature setting. Allow the sealing iron to heat up for
approximately 5 - 7 minutes.
❑After the sealing iron has reached temperature, lightly apply the sealing iron to the wrinkled section of the covering.
Move the sealing iron slowly over the wrinkled section until the covering tightens and the wrinkles disappear.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦You will notice that the color of the covering will darken when it is heated. When the covering cools
back down, it will return to its normal color.
☞If the color layer smears from any of the seams the temperature of the sealing iron is too hot. Turn the temperature dial
down and wait about 5 minutes for the sealing iron to adjust to the lower temperature. You can remove any excess color
streaks using a paper towel soaked with a small quantity of Acetone.
We do not suggest storing your airplane in an extremely hot environment (like the back of your car in direct
sunlight) for any length of time. The extreme heat could cause the covering material to wrinkle or sag and possibly
damage canopy and the fragile components of the radio system.
PRO TIP
F-20 Tigershark 40 ARF - Complete ...................... 127520
Instruction Manual ................................................. 120450
Wing Set ................................................................ 120451
Fuselage Set .......................................................... 120452
Stabilizer Set .......................................................... 120453
Wing Fairings Set .................................................. 120454
Canopy ................................................................... 120455
Fiberglass Cowling ................................................. 120456
Main Landing Gear Set w/Wheels ..........................120457
Hardware Set .......................................................... 120458
Decal Set ................................................................ 120459
Motor Mount Set ..................................................... 120460
Nose Gear Assembly .............................................. 120461

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❑Kwik Bond 30 Minute Epoxy
❑Excel Modeling Knife
❑Ruler
❑Pencil
❑220 Grit Sandpaper w/Sanding Block
❑(1) Right Wing Panel w/Aileron
❑(1) Left Wing Panel w/Aileron
❑(1) Plywood Wing Joiner (W17)
❑(1) Balsa Leading Edge Support (W20)
❑Masking Tape
❑Paper Towels
❑Rubbing Alcohol
❑NHP Epoxy Mixing Sticks
❑NHP Epoxy Mixing Cups
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
SECTION 6: WING ASSEMBLY
STEP 1: ALIGNING THE WING PANELS
❑Using a modeling knife, cut away and remove the excess
covering material that overlaps onto the root ribs of each wing
panel, leaving about 1/16" overlapped so it does not pull away.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦It's very important to the integrity of the
wing center-section joint that you remove as much covering
material from the root ribs as possible. Do not omit this
procedure or the wing center-section joint may fail during flight.
❑Use a ruler and a pencil to locate and draw a vertical
centerline on each side of the plywood wing joiner.
❑Test-fit the plywood wing joiner into the wing joiner box in
each wing panel. It should slide easily into each wing panel up
to the centerline you drew.
☞If the wing joiner does not fit properly, use 220 grit
sandpaper with a sanding block to lightly sand the edges and
tips of the wing joiner, until you are satisfied with the fit.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦The plywood wing joiner is cut in the
shape of a shallow "V." Make sure that this "V" shape is
toward the top of the wing panels.
❑Remove the aileron and three hinges from each of the two wing panels and set them aside for now.
Continued On Next Page
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❑While holding the two wing panels together firmly, make sure that both wing panels are lined up at both the leading and
the trailing edges, then look carefully at the center-section joint: the wing panels should fit together tightly with few or no
gaps in the joint.
☞If the wing panels do not fit together properly, remove the wing joiner and use 220 grit sandpaper with a sanding
block to lightly sand the edges and tips of the wing joiner, until you are satisfied with the fit.
❑Carefully slide both wing panels together with the wing
joiner temporarily installed (without using glue).
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦When the wing joiner is installed, it should
not fit tightly into the wing panels. It should actually be
slightly loose. This will ensure that when you glue the wing
joiner into place epoxy can get into the joints between the
wing joiner and the joiner box. If the wing joiner fits too
tightly, the epoxy will be pushed out of the joints when you
slide the wing joiner into the wing, leaving no glue to secure
it into place.
❑When satisfied with the fit, pull the wing panels apart and
remove the wing joiner.
❑Apply a long strip of masking tape to the top and bottom
edges of the root rib on each wing panel.
☞The masking tape will prevent excess epoxy from getting
onto the wing panels when you join them.
STEP 2: JOINING THE WING PANELS
❑Mix a generous amount of 30 minute epoxy. Working with only one wing panel for now, apply a thin layer of epoxy inside
the wing joiner box and to only half of the wing joiner. Make sure to cover the top and bottom, as well as the sides, and use
enough epoxy to fill any gaps.
✦✦
✦✦
✦WARNING✦✦
✦✦
✦Use only 30 or 45 minute epoxy to install the wing joiner and to join the wing panels together. Do not
use 5 minute epoxy. It is not strong enough.
❑Slide the wing joiner into the wing panel up to its centerline. Quickly remove any excess epoxy, using a paper towel and
rubbing alcohol, and allow the epoxy to set up before proceeding.
❑After the epoxy has set up, test-fit both wing panels together again to double-check that they still fit together properly.
Check the leading and trailing edges, too. It's important that they be even with each other.
❑Mix a generous amount of 30 minute epoxy and apply a thin layer to the exposed half of the wing joiner, the inside of the
wing joiner box in the second wing panel, and to the entire surface of BOTH root ribs. Make sure to use enough epoxy
to fill any gaps.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦It is of the utmost importance to the integrity of the wing center-section joint that you apply a generous
amount of epoxy to both root ribs and to the wing joiner. Not using enough epoxy can result in wing failure during flight.
❑Slide the two wing panels together and realign them. Quickly wipe away any excess epoxy, using a paper towel and
rubbing alcohol, and use pieces of masking tape to hold the two wing panels aligned until the epoxy fully cures.
Continued On Next Page
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10
STEP 3: CHECKING THE WING CENTER-SECTION JOINT
❑Once the epoxy has fully cured, remove the masking tape and double-check the center-section joint. If any gaps are
present, mix a small quantity of 30 minute epoxy and carefully fill any remaining gaps. Quickly remove any excess epoxy,
using a paper towel and rubbing alcohol, and allow the epoxy to thoroughly cure.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦Do not omit this procedure. The wing panels should fit together tightly, but it's possible to have some
small gaps that appear after the epoxy has cured. To make the wing center-section joint as strong as possible, it's
important to fill any gaps, using 30 minute epoxy.
STEP 4: INSTALLING THE BALSA LEADING EDGE SUPPORT
❑Test-fit the balsa leading edge support to the leading edge
of the wing. It should fit firmly against the leading edge of the
wing and the edges of the leading edge support should be even
with the profile of the wing.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦To get a perfect fit, you may need to slightly
enlarge and/or elongate the predrilled holes in the leading
edge support to fit around the wing hold-down dowels.
❑When satisfied with the fit, cut away and remove the covering material from the gluing surfaces, then glue the leading
edge support into place, using a generous amount of 30 minute epoxy. Remove any excess epoxy, using a paper towel
and rubbing alcohol, and hold the leading edge support in place, until the epoxy completely cures, using masking tape.
❑Kwik Bond 5 Minute Epoxy
❑# 2 Phillips Head Screwdriver
❑Excel Modeling Knife
❑Electric Drill
❑13/64" Drill Bit
❑Ernst Airplane Stand
❑Ruler
❑(1) Fuselage w/Hatch Covers
❑(2) Plywood Wing-Screw Doublers
❑(1) Balsa Wing Fairing (Front)
❑(1) Balsa Wing Fairing (Rear)
❑(2) M5 x 40mm Machine Screws
❑(2) M5 Flat Washers
❑Pencil
❑220 Grit Sandpaper w/Sanding Block
❑Masking Tape
❑Paper Towels
❑Rubbing Alcohol
❑NHP Epoxy Mixing Sticks
❑NHP Epoxy Mixing Cups
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
SECTION 7: WING FAIRING INSTALLATION
STEP 1: INSTALLING THE REAR WING FAIRING
❑Using a modeling knife, cut away and remove the covering material from over the top and bottom of the two predrilled
holes in the trailing edge of the wing. The holes are located approximately 7/8" in front of the trailing edge and 2" out
from the centerline.
Continued On Next Page
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11
❑Set the fuselage upside down in your airplane stand. Place the wing into the wing saddle, push it forward completely,
then push the trailing edge down into place.
☞Two holes have been predrilled in the forward bulkhead to accept the wing hold-down dowels in the leading edge
of the wing.
❑Align the predrilled holes in the wing with the predrilled holes in the wing mounting block inside the fuselage, then
secure the wing firmly to the fuselage, using pieces of masking tape, or better yet, a couple of weights.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦It's very important that the wing doesn't move during the next few procedures. It's also very important
that the predrilled holes in the wing line up with the predrilled holes in the wing mounting block.
❑With the wing held firmly in place, position the rear wing
fairing onto the wing. When lined up properly, the sides
and bottom of the wing fairing should be even with the sides
and bottom of the fuselage, and there should be few or no
gaps between the base of the wing fairing and the wing.
The center of the wing fairing (at the front) should be centered
over the wing centerline, too.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦There should be a 1/16" wide gap between
the back edge of the wing fairing and the fuselage.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦If there are gaps between the base of the wing fairing and the wing, use 220 grit sandpaper to sand
away some material from the base of the wing fairing. Remove small amounts of material at a time and recheck the fit
often, until you are satisfied with the fit.
❑When satisfied with the fit and alignment, hold the wing
fairing in place, using strips of masking tape.
❑Use a pencil to draw an outline of the wing fairing onto
the wing.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦Again, it's very important that the wing not
move. It must stay in alignment.
❑Remove the wing from the fuselage, then remove the wing
fairing from the wing and set it aside for now.
❑Using a modeling knife, carefully cut away and remove the
covering material from within the outline you drew.
❑Using a modeling knife, carefully cut away and remove the covering material from the base of the wing fairing.
Continued On Next Page
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☛

12
❑Set the wing back into the wing saddle and realign it. Again, use masking tape or weights to keep the wing firmly in
place and aligned.
❑Mix a generous amount of 5 minute epoxy and apply a thin layer to the gluing surfaces of the wing fairing. Set the wing
fairing back into place and realign it. Remove any excess epoxy, using a paper towel and rubbing alcohol, and hold the
wing fairing firmly in place, until the epoxy sets up.
✦✦
✦✦
✦WARNING✦✦
✦✦
✦Be careful not to get any epoxy between the wing fairing and the fuselage and/or between the wing and
the fuselage. You don't want to accidentally glue the wing to the fuselage.
STEP 2: MOUNTING THE WING
❑After the epoxy completely cures, remove the wing from the fuselage and use a 13/64" diameter drill bit to carefully drill
open the holes in the wing through the wing fairing. Use the predrilled holes in the wing as a guide.
❑Set the wing back into place and align the holes in the wing
with the preinstalled blind nuts in the wing mounting block
inside the fuselage.
❑Secure the wing into place, using two plywood wing-screw
doublers, two M5 x 40mm machine screws and two M5 flat
washers.
☞Don't overtighten the screws. You don't want to crush
the wing.
STEP 3: INSTALLING THE FRONT WING FAIRING
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦It's not necessary, but the two plywood wing-screw doublers can be glued to the wing fairing if you prefer.
❑With the wing installed onto the fuselage, position the front
wing fairing onto the wing. When lined up properly, the
sides and bottom of the wing fairing should be even with
the sides and bottom of the fuselage, and there should be
few or no gaps between the base of the wing fairing and the
wing. The center of the wing fairing (at the back) should
line up over the wing centerline, too.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦There should be a 1/16" gap between the
front edge of the wing fairing and the fuselage.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦If there are gaps between the base of the wing fairing and the wing, use 220 grit sandpaper to sand
away some material from the base of the wing fairing. Remove small amounts of material at a time and recheck the fit
often, until you are satisfied with the fit.
❑Mix a generous amount of 5 minute epoxy and apply a thin layer to the gluing surfaces of the wing fairing. Set the wing
fairing back into place and realign it. Remove any excess epoxy, using a paper towel and rubbing alcohol, and hold the
wing fairing firmly in place, until the epoxy completely sets up.
✦✦
✦✦
✦WARNING✦✦
✦✦
✦Be careful not to get any epoxy between the wing fairing and the fuselage and/or between the wing and
the fuselage. You don't want to accidentally glue the wing to the fuselage.

13
❑Kwik Bond 5 Minute Epoxy
❑Kwik Bond 30 Minute Epoxy
❑Lightweight Oil or Vaseline®
❑Excel Modeling Knife
❑Dubro T-Pins
❑Ernst Airplane Stand
❑Ruler
❑Pencil
❑(1) Horizontal Stabilizer w/Elevator Halves
❑(1) Vertical Stabilizer w/Rudder
❑(1) 2-1/4" Prebent Torque Rod w/Flange Bearing
❑(2) 2-1/2" Prebent Torque Rods w/Flange Bearing
❑Builder's Triangle
❑220 Grit Sandpaper w/Sanding Block
❑Masking Tape
❑Paper Towels
❑Rubbing Alcohol
❑NHP Epoxy Mixing Sticks
❑NHP Epoxy Mixing Cups
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
SECTION 8: STABILIZER INSTALLATION
STEP 1: ALIGNING THE HORIZONTAL STABILIZER
❑Remove the two elevator halves and four hinges from the horizontal stabilizer and set them aside for now.
❑Test-fit the two 2-1/2" long threaded torque rods into the
precut slots in the trailing edge of the stabilizer. The center of
the nylon bearings should be 7-1/4" from the ends of the stabilizer.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦You may need to carefully cut a shallow
bevel in the stabilizer directly above and below each nylon
bearing. The bevel should be deep enough so that when
you push the torque rod into place, the bearing will be slightly
recessed into the trailing edge and there won't be any gap
between the trailing edge and the torque rod wire.
❑When satisfied with the fit, remove the two torque rods and set them aside for now.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦Do not glue the torque rods into the stabilizer at this time. If you glue them into place now, you won't
be able to mount the stabilizer.
❑Using a modeling knife, cut away and remove the covering
material from over the horizontal and vertical stabilizer
mounting slots in the back of the fuselage. The horizontal
stabilizer mounting slots are 6-1/8" long and 1/4" wide, and the
vertical stabilizer mounting slot is 5-3/4" long and 1/4" wide.
✦✦
✦✦
✦PLEASE READ BEFORE PROCEEDING✦✦
✦✦
✦
It's important that you carefully follow the steps and procedures in this section as they are laid out for you. Doing
something out of order may result in you not being able to install the stabilizers correctly.
Continued On Next Page
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14
❑Slide the horizontal stabilizer into the mounting slot and
center it by carefully measuring out from each side of the
fuselage to each end of the stabilizer (at the trailing edge only
for now). When the stabilizer is centered, both measurements
will be equal.
☞The top of the stabilizer is covered red.
❑When you're satisfied that the stabilizer is centered at the
trailing edge, draw a mark on each side of the stabilizer (at
the trailing edge) where it meets the fuselage sides.
❑With the marks on the stabilizer lined up with the fuselage
sides, hold only the trailing edge of the stabilizer in position
using a T-Pin.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦The stabilizer should be pushed forward as far as possible. There will be about a 1/8" wide gap
between the trailing edge of the stabilizer and the mounting slot. This gap is for the torque rods to slide through.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦The front of the stabilizer should be able to pivot from side to side and the back should stay firmly in
place and aligned. The trailing edge should not be allowed to move from side to side.
❑With the wing mounted to the fuselage, use a ruler to
measure the distance between the tips of the stabilizer and the
tips of the wing. Pivot the front of the stabilizer until both of
these measurements are equal.
☞When both of these measurements are equal, you're
assured that the stabilizer is square to the wing.
❑When you are satisfied that the stabilizer is square to the wing, use a pencil to draw a couple of marks on each side of
the front of the stabilizer where it and the fuselage sides meet, then use a couple of pieces of masking tape or T-Pins to
hold the stabilizer firmly in place and aligned.
❑With the stabilizer held firmly in place, look from the front of
the airplane at both the wing and the stabilizer. When aligned
properly, the stabilizer should be parallel to the wing.
☞If the stabilizer is out of alignment, remove it and use 220
grit sandpaper with a sanding block to sand down the higher
side of the stabilizer mounting slot, then reinstall the stabilizer
and check the alignment once more. Repeat this procedure
until you are satisfied with the alignment.
Continued On Next Page
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15
❑With the stabilizer properly aligned, use a pencil to draw a
line on each side of the stabilizer where it meets the fuselage
sides. Do this on both the top and the bottom.
STEP 2: MOUNTING THE HORIZONTAL STABILIZER
❑Mix and apply a generous amount of 30 minute epoxy to ONLY the top and bottom gluing surfaces of the stabilizer.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦Because the stabilizer has to slide into place through the fuselage, apply epoxy only to the stabilizer.
This will prevent the epoxy from spreading over the entire length of one half of the stabilizer when you slide it into place.
❑Slide the stabilizer back into place and realign it, double-checking all of your measurements once more before the
epoxy sets up. Quickly remove any excess epoxy and use pieces of masking tape or T-Pins to hold the stabilizer in place
and aligned until the epoxy has fully cured.
❑After the epoxy has fully cured, remove the masking tape and look closely at the glue joint. If there are any gaps
between the stabilizer and the fuselage, fill them using 30 minute epoxy for added strength. Again, before the epoxy sets
up, remove any excess epoxy, using a paper towel and rubbing alcohol.
❑Remove the stabilizer from the fuselage.
❑Using a modeling knife, carefully cut away and remove the
covering material from between the lines you drew. Do this on
both the top and the bottom.
✦✦
✦✦
✦WARNING✦✦
✦✦
✦When cutting through the covering to remove
it, cut with only enough pressure to cut through only the
covering itself. Cutting down into the balsa structure could
weaken the stabilizer and cause it to fail during flight.
STEP 3: INSTALLING THE ELEVATOR TORQUE RODS
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦Do not glue the elevator torque rods into
place yet. It's important to test-fit them first to ensure they
line up correctly.
❑Notice that there are left and right elevator torque rods.
Working on the left side for now, slide the nylon bearing up
against the threaded end of the torque rod, then slide the
threaded end of the torque rod through the slot behind the
stabilizer trailing edge. At the same time, pivot the nylon
bearing into the slot in the trailing edge, as shown.
Continued On Next Page
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☛

16
❑Gently push the nylon bearing into the slot, then slide the
torque rod into the fuselage, so that the plain end of the torque
rod is near the nylon bearing, as shown.
❑Test-fit the second elevator torque rod into the right side of the elevator, using the same techniques. Again, don't glue
the torque rod into place yet.
❑Turn the fuselage over and remove the control system hatch
cover from the back of the fuselage.
❑Look inside the hatch. The threaded ends of both torque
rods should appear, as shown.
❑When satisfied with the fit and alignment, carefully remove both torque rods and lightly sand the mounting tab on the
nylon bearings, using 220 grit sandpaper.
❑Apply a thin layer of lightweight oil or Vaseline®to only the pivot point of the nylon bearings to prevent epoxy from gluing
the bearings to the torque rod wires.
❑Carefully reinstall the elevator torque rods, using a thin layer of 5 minute epoxy to glue the nylon bearings into the
stabilizer. Remove any excess epoxy, using a paper towel and rubbing alcohol, and allow the epoxy to set up.
✦✦
✦✦
✦WARNING✦✦
✦✦
✦Be careful not to get any epoxy between the nylon bearings and the torque rod wires. You don't want to
glue the torque rod wires solid. They must be able to pivot smoothly.
STEP 4: ALIGNING THE VERTICAL STABILIZER
❑Remove the rudder and the three hinges from the vertical stabilizer and set them aside for now.
❑Test-fit the 2-1/4" long threaded torque rod into the precut
slot in the trailing edge of the stabilizer. The center of the nylon
bearing should be 1/2" up from the bottom of the stabilizer.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦You may need to carefully cut a shallow
bevel in the stabilizer directly to the right and left of the nylon
bearing. The bevel should be deep enough so that when
you push the torque rod into place, the bearing will be slightly
recessed into the trailing edge and there won't be any gap
between the trailing edge and the torque rod wire.
Continued On Next Page
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☛

17
❑When satisfied with the fit, remove the torque rod from the stabilizer and set it aside for now.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦Do not glue the torque rod into the stabilizer at this time. If you glue it into place now, you won't be able
to mount the stabilizer.
❑Push the vertical stabilizer down into its mounting slot. To
align it properly, it should be pushed down firmly and there
should be about a 1/8" wide gap between the trailing edge and
the back of the mounting slot. The vertical stabilizer should be
perpendicular to the horizontal stabilizer, too.
❑While holding the vertical stabilizer firmly in place, use a
pencil to draw a line on each side of the vertical stabilizer where
it meets the top of the fuselage.
❑Remove the vertical stabilizer and use a modeling knife to
carefully cut away and remove the covering material from
below the lines you drew.
✦✦
✦✦
✦WARNING✦✦
✦✦
✦When cutting through the covering to remove
it, cut with only enough pressure to cut through only the
covering itself. Cutting down into the balsa structure could
weaken the stabilizer and cause it to fail during flight.
❑Mix and apply a generous amount of 30 minute epoxy to the gluing surfaces of both the vertical stabilizer and the
vertical stabilizer mounting slot in the top of the fuselage.
❑Push the vertical stabilizer down into place and realign it, double-checking all of your measurements once more before
the epoxy sets up. Quickly remove the excess epoxy and use pieces of masking tape to hold the vertical stabilizer in place
until the epoxy has fully cured.
☞Don't forget to double-check that the vertical stabilizer is perpendicular to the horizontal stabilizer.
STEP 6: INSTALLING THE RUDDER TORQUE ROD
❑Install the rudder torque rod into the vertical stabilizer,
using the same techniques as when you installed the elevator
torque rods into the horizontal stabilizer.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦The threaded portion of the torque rod fits
down through the precut slot in the horizontal stabilizer and
into the control system hatch. Double-check that the torque
rod does not bind against the precut slot.
STEP 5: MOUNTING THE VERTICAL STABILIZER

18
❑Kwik Bond Thin C/A
❑Kwik Bond 5 Minute Epoxy
❑Kwik Bond C/A Debonder
❑Lightweight Oil or Vaseline®
❑Excel Modeling Knife
❑220 Grit Sandpaper w/Sanding Block
❑(3) Nylon Adjustable Control Horns (Small Thread) ❑(13) C/A Style Hinges
❑Waxed Paper
❑Paper Towels
❑Rubbing Alcohol
❑NHP Epoxy Mixing Sticks
❑NHP Epoxy Mixing Cups
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
SECTION 9: CONTROL SURFACE HINGING
STEP 1: HINGING THE AILERONS
✦✦
✦✦
✦WARNING✦✦
✦✦
✦For flutter-free control surfaces, it is imperative that the hinges be glued in properly. This is achieved by
having a tight hinge gap and using plenty of thin C/A glue. Poor hinge installation can lead to control surface flutter which
can result in a catastrophic failure of the airframe. It's important to use a generous amount of epoxy to glue the torque
rods into the control surfaces, too. This will result in more positive control.
❑Using a modeling knife, carefully cut away and remove the
covering material from over the precut slot in the root end of
one aileron.
☞Notice that there is a predrilled hole in the slot to accept
the aileron torque rod wire.
❑Slide one hinge into each hinge slot in the aileron, making
sure that you push each hinge in up to the T-pins. Don't glue
the hinges into place yet.
❑Push the aileron and its hinges into the hinge slots in the trailing edge of the wing, making sure that the torque rod wire
is firmly seated within the slot in the aileron. The aileron should be pushed firmly up against the trailing edge, so that there
is a minimal hinge gap (no more than 1/32" wide), and the ends of the aileron should not rub against the wing.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦You may need to cut the slot in the aileron for the torque rod wire deeper so that the aileron can be
pushed forward enough to result in no more than a 1/32" wide hinge gap.
❑Push two T-pins through the center of three C/A style aileron hinges. The T-pins will keep the hinges centered while
you are hinging the aileron.
Continued On Next Page
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☛☛
☛

19
❑Cut out a 1-1/2" square piece of waxed paper.
❑Slide the waxed paper between the torque rod wire and the
trailing edge of the wing.
☞The waxed paper will prevent epoxy from gluing the torque
rod to the trailing edge.
❑When satisfied with the fit, remove the aileron from the wing, but leave the hinges in the aileron.
❑Using 220 grit sandpaper, lightly sand the end of the torque rod wire to roughen the surface, then mix a small quantity
of 5 minute epoxy and apply a thin layer to the end of the aileron torque rod wire and into the predrilled hole and the precut
slot in the leading edge of the aileron.
❑Push the aileron and its hinges into the hinge slots in the trailing edge of the wing and align the aileron as done
previously.
❑Remove the T-pins from the hinges, and while holding the
aileron tight against the wing, pivot the aileron down about
45º and apply 5-6 drops of thin C/A to the exposed area of
each hinge. Turn the wing over and repeat for the other side of
the hinges.
☞Remove any C/A that may run down the hinge line, using
C/A Debonder.
❑Allow the C/A and epoxy to dry for about 15 minutes, then
pivot the aileron up and down several times to free up the hinges.
After the C/A and epoxy have fully cured, gently grasp the aileron and wing and pull on the aileron like you
are trying to pull out the hinges. The hinges should hold securely. If one or more hinges feels loose, apply more C/A
to the hinge(s) and allow it to completely cure.
❑Repeat the previous procedures to hinge the second aileron to the wing, making sure to check the integrity of
the hinges after the C/A and epoxy fully cure.
PRO TIP
STEP 2: HINGING THE ELEVATOR HALVES
❑Carefully thread one nylon adjustable control horn onto each
threaded elevator torque rod wire. The control horns should
both face the front of the fuselage and they should both be
flush with the top of the torque rod wires, too.
☞It's much easier to thread the control horns into place now,
rather than waiting until after you've hinged the elevator halves.
Continued On Next Page
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☛☛
☛

20
❑Using a modeling knife, carefully cut away and remove the
covering material from over the precut slot in the root end of
one elevator half.
☞Notice that there is a predrilled hole in the slot to accept
the elevator torque rod wire.
✦✦
✦✦
✦IMPORTANT✦✦
✦✦
✦You may need to carefully cut a shallow bevel in the elevator half directly above and below the location
where the elevator half and the nylon torque rod bearing meet. The bevel should be deep enough so that when you
hinge the elevator half to the stabilizer there won't be more than a 1/32" wide hinge gap.
❑Remove the elevator half from the stabilizer, but leave the hinges in the elevator half for now. Using 220 grit sandpaper,
lightly sand the end of the torque rod wire to roughen the surface, then mix a small quantity of 5 minute epoxy and apply a
thin layer to ONLY the end of the torque rod wire and into the predrilled hole in the leading edge of the elevator half.
✦✦
✦✦
✦WARNING✦✦
✦✦
✦Do not get epoxy between the elevator half and the nylon torque rod bearing. You don't want to glue the
elevator half to the nylon bearing or the elevator half won't pivot up and down.
❑Push the elevator half and its hinges into the hinge slots in the stabilizer and align the elevator half as done previously.
❑Remove the T-pins from the hinges, and while holding the elevator half tight against the stabilizer, pivot the elevator
half down about 45º and apply 5-6 drops of thin C/A to the exposed area of each hinge. Turn the fuselage over and
repeat for the other side of the hinges.
☞Remove any C/A that may run down the hinge line, using C/A Debonder.
❑Allow the C/A and epoxy to dry for about 15 minutes, then pivot the elevator half up and down several times to free
up the hinges.
After the C/A and epoxy have fully cured, gently grasp the elevator half and stabilizer and pull on the
elevator half like you are trying to pull out the hinges. The hinges should hold securely. If one or more hinges feels
loose, apply more C/A to the hinge(s) and allow it to completely cure.
❑Push two T-pins through the center of two C/A style elevator hinges. The T-pins will keep the hinges centered while
you are hinging the elevator half.
❑Slide one hinge into each hinge slot in the elevator half, making sure that you push each hinge in up to the T-pins. Don't
glue the hinges into place yet.
❑Push the elevator half and its hinges into the hinge slots in
the stabilizer, making sure that the torque rod wire is firmly
seated within the slot in the elevator half. The elevator half
should be pushed firmly up against the trailing edge, so that
there is a minimal hinge gap (no more than 1/32" wide). The
tip of the elevator half should be even with the tip of the
stabilizer and there should be about a 1/16" wide gap between
the elevator half and the fuselage side.
PRO TIP
Continued On Next Page
☛☛
☛☛
☛