Sportsman Aviation Giant Scale Corby Starlet User manual

Page 1
FEATURES AND SPECIFICATIONS
ASSEMBLY INSTRUCTIONS
Kit Product Number 127533
Scale: 38.5% lWing Span: 85.85 Inches (2181mm) lWing Area: 1455 Square Inches (93.8dm2) lLength: 70.39 Inches (1788mm)
Weight RTF: 17.25 Pounds (7.8kg) l Wing Loading: 27 Ounces/Square Foot (95gr/dm2) lFunctions: Ailerons, Elevator, Rudder and Throttle
Engine Required: 1.80 Two-Stroke or 1.80 - 2.10 Four-Stroke lRadio Required: 4-Channel or More w/5 High-Torque Ball Bearing Servos
Made in China
lPrecision-Built, CAD-Designed Airframe for Light Weight and High Strength
lLaser-Cut, Balsa and Plywood Construction
lPremium Iron-On Covering in Detailed Scale Color Scheme
l Aluminum Main Landing Gear Brackets and Tail Wheel Assembly
lPrepainted Fiberglass Cowling, Wheel Pants and Clear Molded Canopy
l Strong, Aluminum Adjustable Engine Mounting Beams
lDual Aileron Servos, Pull-Pull Rudder Cables and Reinforced Split Elevator Pushrod
lIncludes High-Quality Hardware
lFast and Easy Assembly - Over 100 High-Resolution Digital Photos and Drawings
All Contents Copyright © 2006, Global Hobby Distributors
Version 1 December 2006
The Sportsman Aviation Giant Scale Corby StarletARF is distributed
exclusively in the USA by Global Hobby Distributors
and in Australia by Tates Performance Hobbies
The Corby Starlet is the rst post-war Australian designed single seat aircraft to y in Australia. The Starlet was designed and built by John Corby and
Barrie Bishton of Sydney N.S.W. Australia. This design placed fourth in a world-wide design competition for small racing aircraft conducted by Rollason
LTD in England in 1964. The prototype Corby Starlet rst ew on the 9th of August 1967 in the small country town of Camden. Unknown at the time
to the model designer (Chris White) the prototype Corby Starlet model also had its maiden ight at the same town of Camden nearly 38 years later.
The Full-Size Starlet was a semi-aerobatic sports airplane made of an all-wood construction. The fuselage is a combination of spruce longerons and
frames and is sheeted with plywood. The wing is a single-piece structure, consisting of a solid laminated spar and built-up ribs. The D-nose leading
edge is plywood covered. The remainder of the wing, including the ailerons, is open-structure and fabric covered. The main undercarriage consists
of spring-steel legs bolted to a stiffened frame in the fuselage, immediately behind the rewall. To this day many examples of this aircraft are own in
countries all over the world.
Every attempt has been made to make the 38.5% model version of the Corby Starlet as scale as possible with only minor changes being made to
enhance ying characteristics. Indeed even the color scheme is modeled from a full size plane ying today. The prototype model was own with a
Magnum XL-180RFS and the model is very well suited to this motor combination. Great care should be taken when setting up any new model and all
the travel throws and C/G should be measured and kept as close as possible to the recommended settings as described in the assembly instructions.
This will allow maximum ight performance with maximum enjoyment factor!
You will nd the Giant Scale Corby Starlet very easy to take-off and land. Once you have some time under your belt, you can really wring-it-out
pushing the envelope even beyond the full-scale!

Page 2



These assembly instructions are 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.
lPlease read through each step before beginning assembly. You
should nd 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.
lThere 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.
lCover your work table with brown paper or a soft cloth, both to
protect the table and to protect the parts.
lKeep a couple of small bowls or jars handy to put the small parts
in after you open the accessory bags.
lWe'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 ying
airplane.
lIf you come across this symbol ☞, it means that this is an
important point or an assembly hint.
INTRODUCTION
TABLE OF CONTENTS
CUSTOMER SERVICE INFORMATION
Global Hobby Distributors will not disclose the information it collects to outside parties. We do not sell, trade, or rent your personal information to others . Your privacy is important to us.
IMPORTANT INFORMATION ABOUT YOUR EMAIL ADDRESS
In the USA
Global Services
18480 Bandilier Circle
Fountain Valley, CA 92708
Phone: [phone] Fax: [phone]
Email: [e-mail]
Check out our support website at http://globalservices.globalhobby.com. There you will nd public message boards frequented by other Sportsman Aviation product owners
and our technical support staff. This is a great place to get quick answers and advice on your new product.
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.
In Australia
Tates Performance Hobbies
135 Shannon Avenue
Geelong West 3218
Victoria, Australia
Phone: [phone] Email: [email protected]
INTRODUCTION..................................................................................................... 2
SAFETY WARNING ................................................................................................ 2
CUSTOMER SERVICE INFORMATION ................................................................. 2
OUR RECOMMENDATIONS .................................................................................. 3
TOOLS AND SUPPLIES REQUIRED ..................................................................... 4
A NOTE ABOUT COVERING MATERIAL ............................................................... 4
TIPS FROM THE PROS.......................................................................................... 4
KIT CONTENTS ...................................................................................................... 5
WING ASSEMBLY................................................................................................... 7
MOUNTING THE WING .......................................................................................... 9
STABILIZER INSTALLATION ................................................................................ 10
TAIL WHEEL INSTALLATION................................................................................ 13
LANDING GEAR INSTALLATION ......................................................................... 14
ENGINE INSTALLATION....................................................................................... 16
THROTTLE CONTROL SYSTEM INSTALLATION ............................................... 17
FUEL TANK ASSEMBLY AND INSTALLATION..................................................... 18
ELEVATOR CONTROL SYSTEM INSTALLATION................................................ 20
RUDDER CONTROL SYSTEM INSTALLATION................................................... 24
AILERON CONTROL SYSTEM INSTALLATION .................................................. 27
COWLING INSTALLATION ................................................................................... 29
CANOPY INSTALLATION ..................................................................................... 30
FINAL ASSEMBLY................................................................................................. 31
C/G AND BALANCING .......................................................................................... 32
LATERAL BALANCING ......................................................................................... 32
AIRCRAFT SETUP INFORMATION...................................................................... 33
PREFLIGHT CHECK AND SAFETY ..................................................................... 34
OUR GUARANTEE ............................................................................................... 34
PRODUCT EVALUATION SHEET......................................................................... 35
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 ying site. We suggest having a qualied instructor carefully inspect your airplane before
its rst ight. Please carefully read and follow all instructions included with this airplane, your radio control system and any other
components purchased separately.
SAFETY WARNING

Page 3
This section describes our recommendations to help you in deciding which types of accessories to purchase for your new airplane.
Please read through this entire section very carefully. We have provided you with recommendations that,
if followed, will result in a great ying airplane. Failure to follow our recommendations may result in a poor
ying airplane.
OUR RECOMMENDATIONS
WHAT ENGINE SHOULD I USE?
WHAT RADIO SYSTEM AND SERVOS SHOULD I USE?
HERE'S A LIST OF WHAT WE USED TO FINISH THE GIANT SCALE CORBY STARLET ARF SHOWN IN THESE INSTRUCTIONS
QTY. 1 Hitec Optic 6 FM Radio Control System
QTY. 1 210989 Magnum XL 1.80RFS Four-Stroke Engine
QTY. 1 237159 Magnum 3-3/4" Diameter Chrome Spinner
QTY. 1 609792 APC 17 x 8 Composite Propeller
QTY. 5 440601 Cirrus CS601 Standard Ball Bearing Servos
QTY. 2 444713 Cirrus 12" Servo Extension Leads
QTY. 2 444718 Cirrus 24" Servo Extension Leads
QTY. 1 115480 Thunderbolt HP Four-Stroke Glow Plug
QTY. 1 115923 Global XX Silicone Fuel Tubing
QTY. 1 237500 Magnum Fueling Valve
QTY. 1 868638 Dubro 1/4" Protective Foam Rubber
The Giant Scale Corby Starlet ARF can be own using either a 1.80 size two-stroke engine or a 1.80 - 2.10
size four-stroke engine. A 35cc - 40cc gasoline engine would work well, too. The airplane will y great using
any engine within the recommended size range, although for the best aerobatic performance we suggest
using an engine toward the higher end of the suggested size range.
For the best ight performance, we suggest trying to keep the ready-to-y weight of the airplane as light
as possible. Using an engine that's bigger than recommended will only add extra weight to the airplane,
negating any of the extra power from the larger engine and increasing the wing loading. In most cases, you'll
get better ight performance from a lightweight but powerful engine, than from simply a higher displacement
engine. We don't suggest using an engine that's outside of the recommended size range.

WHAT OTHER ITEMS DO I NEED?
IMPORTANT The Cirrus servos are compatible with all receiver types. The Cirrus servo extensions are compatible with Hitec and JR radio control
systems. These items are also available with connectors that are compatible with Futaba and Airtronics radio control systems. The Magnum spinner
includes a 3/8" x 5mm adapter nut that ts any engine that uses a 3/8"-24 threaded crankshaft.
To get the most out of the airplane, we suggest using a four or more channel computer radio system with mixing capabilities. Since
there are two separate aileron servos used, they can be plugged separately into
the receiver, allowing you the capability of aperon and spoileron mixing, differential
mixing and aperon/spoileron to elevator mixing.
Because of the size of the airplane, using high-torque ball bearing servos is a must.
For crisp, positive control, we suggest using high-quality, dual ball bearing servos
with a minimum of 75oz/in of torque on the ight control surfaces. For throttle
control, a standard ball bearing servo can be used. Although you would lose mixing
capabilities, the airplane can be own using a basic four-channel radio control system. If you do this, you will need to use a servo
Y-Harness to join the two aileron servos together.
There really isn't too much else that you'll need to nish the airplane. Most of the hardware is included, so about the only thing else
you'll need is a spinner, remote fueling valve and four servo extension leads. For more scale realism, a pilot bust or even a full-length
pilot would be a good choice. You'll also need typical modeling supplies, such as foam rubber to protect your receiver and battery,
and fuel tubing.
QTY. 1 867903 Dubro 3/8" Heat-Shrink Tubing
QTY. 1 567032 Dubro Foam Wing Saddle Tape (Optional)
QTY. 1 869697 Dubro Exhaust Deector

Page 4
❑Straight Edge Ruler
❑Pencil
❑Airplane Stand
❑T-Pins
❑Builder's Triangle
❑Rotary Tool with Cutting Disc and Sanding Drum
❑220 Grit Sandpaper with Sanding Block
❑Masking Tape
❑Paper Towels
❑Rubbing Alcohol
❑Epoxy Mixing Sticks
❑Epoxy Mixing Cups
❑Heat-Sealing Iron
❑Heat Gun
❑5 and 30 Minute Epoxy
❑Thin and Thick C/A (Cyanoacrylate)
❑Formula 560 Canopy Glue
❑C/A Debonder
❑Silicon Sealant
❑# 1 and # 2 Phillips Head Screwdrivers
❑3mm, 4mm and 6mm Hex Wrenches
❑4mm and 8mm Nut Drivers
❑Adjustable Wrenches (2)
❑Wire Cutters
❑Needle Nose Pliers
❑Modeling Knife
❑Scissors
❑Electric Drill
❑Assorted Drill Bits
TIPS FROM THE PROS
lDuring the covering process, sometimes color may smear slightly from the seams. If you see any smeared colors on the covering
material, it can be quickly removed by simply wiping it off with a paper towel and a small amount of acetone.
l Make sure to test-t the parts together before applying glue. This will ensure that the parts t properly before gluing them together.
lWhen gluing anything that has a smooth surface, it's important to lightly roughen the gluing surfaces with 220 grit sandpaper. This
will allow the glue to stick better. Also, never glue directly to the covering material. Always remove the covering material from the
gluing surfaces prior to gluing the parts together.
lWhen cutting away the covering material from the gluing surfaces, be careful to cut only through the covering material. Try not to
cut down into the balsa structure because that can compromise the integrity of the airframe.
lWe 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 the fragile components of the
radio control system.
lEpoxy can be cleaned up before it dries using rubbing alcohol and C/A can be cleaned up before it dries using C/A Debonder.
TOOLS AND SUPPLIES REQUIRED
The covering material used on your airplane is real iron-on, heat-shrink covering material. It is possible with heat and humidity changes
that the covering material 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 use a heat-sealing covering iron.

❑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 material. Move
the sealing iron slowly over the wrinkled section until the covering material tightens and the wrinkles disappear.
A NOTE ABOUT COVERING MATERIAL
☞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.
IMPORTANT You will notice that the color of the covering material will darken when it is heated. When the covering material
cools back down, it will return to its normal color.

Page 5
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.
IF YOU FIND ANY PARTS MISSING OR DAMAGED, PLEASE CONTACT US DIRECTLY, USING THE CUSTOMER SERVICE INFORMATION ON PAGE 2.
KIT CONTENTS
AIRFRAME ASSEMBLIES
❑(1) Fuselage with Vertical Stabilizer
❑(1) Right Wing Panel with Aileron
❑(1) Left Wing Panel with Aileron
❑(1) Horizontal Stabilizer with Elevator Halves
❑(1) Rudder
❑(2) Wheel Pants
❑(2) Landing Gear Brackets
❑(2) Main Gear Wheels
❑(2) Threaded Axle Shafts
❑(6) M4 x 20mm Socket-Cap Screws
❑(6) M4 Flat Washers
❑(2) M8 Hex Nuts
❑(2) Wheel Collars with Grub Screws
❑(2) M3 x 12mm Wood Screws
❑(1) Tail Wheel Bracket
❑(1) Tail Wheel Wire with Tail Wheel and Wheel Collar
❑(2) M3 x 16mm Flange-Head Wood Screws
❑(1) Wheel Collar with Grub Screw
❑(1) Split Elevator Pushrod Assembly
❑(1) Pushrod Support Plate
❑(2) Threaded Control Horns
❑(2) Control Horn Backplates
❑(2) Adjustable Control Horns
❑(2) Clevises
❑(1) Snap-Keeper
❑(6) M2 x 50mm Machine Screws
❑(6) C/A-Style Hinges
❑(1) Heat-Shrink Tubing
MAIN LANDING GEAR ASSEMBLY
TAIL WHEEL ASSEMBLY
ELEVATOR CONTROL SYSTEM ASSEMBLY
AILERON CONTROL SYSTEM ASSEMBLY
❑(2) 8" (203mm) Threaded Pushrod Wires
❑(2) Threaded Control Horns
❑(2) Control Horn Backplates
❑(2) Adjustable Control Horns
❑(2) Clevises
❑(2) Snap-Keepers
❑(6) M2 x 50mm Machine Screws
❑(8) C/A-Style Hinges
❑(1) Heat-Shrink Tubing

Page 6
❑(2) Adjustable Engine Mounting Beams
❑(4) M5 x 25mm Socket-Cap Screws
❑(4) M5 x 30mm Socket-Cap Screws
❑(8) M5 Flat Washers
❑(4) M5 Lock Nuts
❑(4) M5 Blind Nuts
❑(1) 500cc Fuel Tank
❑(3) Aluminum Tubing
❑(1) Rubber Stopper
❑(1) Large Metal Plate
❑(1) Small Metal Plate
❑(1) Silicone Fuel Tubing with Clunk
❑(1) M3 x 18mm Machine Screw
❑(1) Stranded Pull-Pull Cable
❑(2) Threaded Control Horns
❑(2) Clevises
❑(2) Adjustable Control Horns
❑(2) Couplers with Z-Bends
❑(2) Threaded Couplers
❑(4) Flanged Crimp Collets
❑(3) M2 x 50mm Machine Screws
❑(3) M2 Flat Washers
❑(3) M2 Hex Nuts
❑(5) C/A-Style Hinges
❑(1) Heat-Shrink Tubing
❑(1) 14" (356mm) Pushrod Wire with Z-Bend
❑(1) Adjustable Pushrod Connector Assembly with Grub Screw
❑ (1) Aluminum Wing Joiner Tube
❑(1) Hardwood Dowel
❑(2) M8 x 50mm Socket-Cap Screws
❑(2) M8 Flat Washers
❑(1) Cowling
❑(1) Canopy
❑(1) Cockpit Deck
❑(3) Plywood Servo Trays (Elevator, Rudder and Throttle)
❑(2) Balsa Support Sticks (Long)
❑(1) Balsa Support Stick (Short)
❑(9) M2 x 10mm Flange-Head Wood Screws
❑(20) M2 x 8mm Flange-Head Wood Screws
❑(1) Hex Wrench
RUDDER CONTROL SYSTEM ASSEMBLY
THROTTLE CONTROL SYSTEM ASSEMBLY
ENGINE MOUNT ASSEMBLY
FUEL TANK ASSEMBLY
MISCELLANEOUS WING PARTS
MISCELLANEOUS FUSELAGE PARTS

Page 7
WING ASSEMBLY
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
STEP 1: HINGING THE AILERONS
IMPORTANT The hinges are NOT glued into place from the factory, they are simply slid into place dry for shipping purposes.
You must glue them into place.
C/A-style hinges are used to hinge the control surfaces. These hinges are designed to be glued into place using thin C/A. Do not
glue these hinges into place using any other type of glue, such as thick C/A or epoxy. Use of any adhesive other than thin C/A
could result in failure of the hinges during ight.
For utter-free control surfaces and crisp control response, it is imperative that the hinges be glued in properly. This is achieved
by having a tight hinge gap (no more than 1/32" (.7mm) wide) and using plenty of thin C/A glue. Poor hinge installation can lead
to control surface utter which can result in a catastrophic failure of the airframe.
❑Push the aileron and hinges into the corresponding four hinge slots in
the trailing edge of the matching wing panel.
❑Thin C/A
❑C/A Debonder
❑# 1 Phillips Head Screwdriver
❑Modeling Knife
❑Electric Drill
❑(1) Right Wing Panel with Aileron
❑(1) Left Wing Panel with Aileron
❑(8) C/A-Style Hinges
❑1/16" (1.6mm) Drill Bit
❑Straight Edge Ruler
❑Pencil
❑T-Pins
❑Paper Towels
IMPORTANT Each C/A-style hinge has two slots cut in it. These slots help wick the thin C/A glue deep into the hinge slot, ensuring
a strong bond. When sliding the hinges into place, make sure that the slots are perpendicular to the hinge line.
❑Push two T-Pins through the center of four C/A-style hinges.
PRO TIP The T-Pins will keep the hinges centered and square to the
hinge line while you are hinging the aileron.
❑Slide one hinge into each of the four hinge slots in one aileron, making
sure that you push each hinge in up to the T-Pins.
IMPORTANT Don't glue the hinges into the aileron yet.

Page 8
❑Allow the C/A to dry for about 15 minutes and pivot the aileron up and down several times to free up the hinges, then repeat the
previous procedures to hinge the second aileron to the other wing panel.
❑Remove the T-Pins and push the aileron up against the trailing edge.
There should be no more than a 1/32" (.7mm) wide hinge gap and the tip of
the aileron counter-balance should be even with the tip of the wing.
❑While holding the aileron tight against the trailing edge, pivot the aileron
down 45º and apply 5-6 drops of thin C/A to the exposed area of each hinge,
then turn the wing panel over and repeat for the other side of the hinges.
IMPORTANT Check the integrity of the hinges after the C/A fully cures by gently pulling on the ailerons. If one or more hinges
feels loose, apply more C/A to the hinge(s) and allow it to completely cure. The last thing you want is for a hinge to come loose
during ight.
STEP 2: INSTALLING THE AILERON SERVOS
❑Plug one 24" (610mm) servo extension onto the aileron servo lead.
❑To prevent the plugs from pulling apart during assembly, or worse, during
ight, secure the plugs together, using a short piece of 3/8" (9.5mm) diameter
heat-shrink tubing (not included). Use a heat gun to shrink the tubing.
❑Cut away the covering material from over the aileron servo mounting hole
in the bottom of one wing panel. The servo mounting hole is located 23-3/4"
(603mm) out from the root end of the wing panel and 3-3/4" (95mm) in front
of the aileron hinge line.
❑Cut away the covering material from over the aileron servo lead exit hole
in the top of the same wing panel. The servo lead exit hole is located 1"
(25mm) out from the root end of the wing panel and 11-1/4" (286mm) in front
of the trailing edge.
❑Tie the end of the length of string that's inside the servo mounting hole
to the servo extension plug, then pull the string from the other end to guide
the servo extension lead out through the top of the wing panel.
❑ Install the rubber grommets and brass collets onto one aileron servo, making sure to install the collets with the anges toward the
bottom of the servo.

Page 9
❑Install the aileron servo into the mounting hole, making sure to drill 1/16"
(1.6mm) diameter pilot holes for the mounting screws, then repeat the previous
procedures to install the aileron servo into the second wing panel.
IMPORTANT The servo output shaft should be toward the trailing
edge of the wing.
MOUNTING THE WING
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑30 Minute Epoxy
❑8mm Hex Wrench
❑Modeling Knife
❑Straight Edge Ruler
❑Airplane Stand
❑(1) Fuselage with Vertical Stabilizer
❑ (1) Aluminum Wing Joiner Tube
❑(1) Hardwood Dowel
❑(2) M8 x 50mm Socket-Cap Screws
❑(2) M8 Flat Washers
❑Paper Towels
❑Rubbing Alcohol
❑Epoxy Mixing Sticks
❑Epoxy Mixing Cups
STEP 1: JOINING THE WING PANELS
❑Epoxy the hardwood dowel into one wing panel, making sure to push the
hardwood dowel into the wing panel until it bottoms out.
❑Slide the aluminum wing joiner tube into one wing panel, making sure to
push the wing joiner tube into the wing panel until it bottoms out.
IMPORTANT Do not glue the aluminum wing joiner tube into the wing panel and don't glue the two wing panels together. The wing
panels are designed to be removable for easier transport and storage.
❑Slide the second wing panel onto the aluminum wing joiner tube, then
push the two wing panels together rmly, making sure that the two wing
panels t together tightly.
IMPORTANT The wing panels are supported during ight by the aluminum
wing joiner tube and are prevented from sliding apart by the two dowels at
the front of the wing and the two wing hold-down screws.

Page 10
STEP 2: MOUNTING THE WING
❑Cut away and remove the covering material from over the top and bottom
of the two predrilled wing-screw holes in the trailing edge of the wing. The
wing screw holes are located 2-5/8" (67mm) out from the center wing joint
and 2-5/8" (67mm) in front of the trailing edge.
❑Place the wing into the wing saddle, push it forward completely, then push
the trailing edge down into place.
☞Two holes have been predrilled into the forward bulkhead to accept the
wing hold-down dowels in the leading edge of the wing.
❑Align the holes in the wing with the preinstalled blind nuts in the wing
mounting block inside the fuselage, then secure the wing into place, using
two M8 x 50mm socket-cap screws and two M8 at washers.
☞Don't overtighten the screws. You don't want to crush the wing.
IMPORTANT Plywood plates are preinstalled in the wing to tighten the wing mounting screws against. It is not necessary to
use separate wing-screw doublers.
❑ Turn the fuselage over and check the t between the wing and the wing saddle. There shouldn't be any gaps between the two.
If there are any small gaps, we suggest that you apply a strip of foam wing tape (not included) to the wing saddle to seal the gaps.
This will prevent fuel from getting inside the fuselage during ight.
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑30 Minute Epoxy
❑Thin C/A
❑C/A Debonder
❑Modeling Knife
❑Straight Edge Ruler
❑Pencil
❑Airplane Stand
❑(1) Horizontal Stabilizer with Elevator Halves ❑(6) C/A-Style Hinges
❑T-Pins
❑220 Grit Sandpaper with Sanding Block
❑Masking Tape
❑Paper Towels
❑Rubbing Alcohol
❑Epoxy Mixing Sticks
❑Epoxy Mixing Cups

❑Remove the elevator halves and hinges from the stabilizer and set them aside for now.


Page 11
❑Cut away the covering material from over the stabilizer mounting slot in
each side of the fuselage.
❑Slide the 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 stabilizer's airfoil and color scheme are symmetrical, so choose the
best looking side for the top.
❑ When you're satised 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 front of the stabilizer should be able to pivot from side to side and the back should stay rmly 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're satised that the stabilizer is square to the wing, use a pencil
to draw a mark on each side of the front of the stabilizer where it and the
fuselage sides meet, then use a couple of T-Pins to hold the stabilizer rmly
in place and aligned.
❑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 not parallel to the wing, you'll need to remove the stabilizer and
sand down the higher side of the stabilizer mounting slot until you're satised
with the alignment.

Page 12

❑ Once you're satised with the alignment, draw a line on each side of the
stabilizer where it meets the fuselage. Do this on both the top and the
bottom.
WARNING When cutting through the covering to remove it in the next procedure, 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 ight.
❑Remove the stabilizer from the fuselage, then carefully cut away the
covering material from inside the lines you drew. Cut away the covering
material from both the top and the bottom of the stabilizer.
PRO TIP Use a heat-sealing iron to adhere the covering material down
where you cut it. This will prevent it from loosening up and wrinkling.
❑To make it less messy during installation, apply masking tape to the
fuselage around the side of the mounting slot that the stabilizer will slide into.
Apply masking tape to the top and bottom of the corresponding side of the
stabilizer, too, then partially slide the stabilizer into the mounting slot.
❑Apply a generous amount of 30 minute epoxy to ONLY the top and bottom gluing surfaces of the stabilizer.
❑Push the stabilizer 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 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, ll 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.
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.
STEP 3: HINGING THE ELEVATOR HALVES
❑Hinge the elevator halves, using the same techniques that you used to
hinge the ailerons. Each elevator half is hinged using three hinges. When
hinging the elevator halves, the tip of the elevator counter-balances should
be even with the tips of the stabilizer and there should not be more than a
1/32" (.7mm) wide hinge gap.
IMPORTANT After allowing the C/A to fully cure, pull on the elevator halves to check the integrity of the hinges. Apply more
C/A to the hinge(s) if necessary.

Page 13
TAIL WHEEL INSTALLATION
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑5 Minute Epoxy
❑Thin C/A
❑C/A Debonder
❑# 2 Phillips Head Screwdriver
❑Wire Cutters
❑Needle Nose Pliers
❑Modeling Knife
❑Electric Drill
❑5/64" (2mm) and 3/32" (2.4mm) Drill Bits
❑(1) Rudder
❑(1) Tail Wheel Bracket
❑(1) Tail Wheel Wire with Tail Wheel and Wheel Collar
❑(2) M3 x 16mm Flange-Head Wood Screws
❑(1) Wheel Collar with Grub Screw
❑(5) C/A-Style Hinges
❑(1) Hex Wrench
❑Straight Edge Ruler
❑Pencil
❑Airplane Stand
❑T-Pins
❑220 Grit Sandpaper with Sanding Block
❑Paper Towels
❑Rubbing Alcohol
❑Epoxy Mixing Sticks
❑Epoxy Mixing Cups
❑Slide the wheel collar, followed by the aluminum mounting bracket, onto
the tail wheel wire, making sure that the bushing on the tail wheel bracket is
toward the coil in the tail wheel wire.
❑Carefully make a 90º bend in the tail wheel wire, 2-1/4" (57mm) up from
the top of the coil.
❑Cut off the excess wire, leaving 1-1/8" (29mm) of wire beyond the bend.
STEP 1: INSTALLING THE TAIL WHEEL WIRE
❑Measure up 1-1/8" (29mm) from the bottom of the rudder (at the leading
edge) and draw a mark.
❑Drill a 3/32" (2.4mm) diameter hole, 1-1/4" (32mm) deep into the leading
edge of the rudder at the mark you drew.
IMPORTANT Make sure that you drill the hole perpendicular to the
leading edge.
❑Cut a shallow groove in the leading edge of the rudder from the base of
the hole down to the bottom of the rudder.
❑ Test-t the tail wheel wire into the hole and groove. When properly aligned,
the tail wheel wire should rest within the groove and the front edge of the tail
wheel wire should be ush with the leading edge of the rudder.
IMPORTANT Double-check that the tail wheel is lined up with the
bottom of the rudder. This will ensure that the tail wheel will track straight
with the rudder.
2-1/4"
(57mm)
1-1/8"
(29mm)
1-1/8"
(29mm)

Page 14
❑ When satised with the t and alignment, remove the tail wheel wire and use 220 grit sandpaper to roughen only the gluing
surfaces of the wire.
❑Glue the tail wheel wire into place, using a generous amount of 5 minute epoxy. Remove any excess epoxy, using a paper towel
and rubbing alcohol, and allow the epoxy to set up before proceeding.
STEP 2: HINGING THE RUDDER
IMPORTANT After allowing the C/A to fully cure, pull on the rudder
to check the integrity of the hinges. Apply more C/A to the hinge(s) if
necessary.
❑Hinge the rudder, using the same techniques that you used to hinge the
elevator halves. The bottom of the rudder should be even with the bottom
of the fuselage and the rudder counter-balance should not rub against the
top of the vertical stabilizer, and there should not be more than a 1/32"
(.7mm) wide hinge gap.
❑Mount the tail wheel bracket to the bottom of the fuselage (making sure
that it's centered), using two M3 x 16mm ange-head wood screws. Make
sure to rst drill two 5/64" (2mm) diameter pilot holes for the wood screws.
IMPORTANT Before installing the wood screws, drip several drops of
thin C/A into the pilot holes and allow the C/A to fully cure. The C/A will
harden the surrounding plywood, making the mounting area stronger.
❑ Push the wheel collar against the tail wheel bracket, then install and tighten the grub screw rmly.
PRO TIP It's important that the wheel collar be pushed rmly against the tail wheel bracket. The wheel collar will help the tail
wheel bracket absorb the forces of the tail wheel from the rudder during use. If the wheel collar is not pushed against the tail wheel
bracket, damage to the rudder may occur over time.
LANDING GEAR INSTALLATION
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑# 2 Phillips Head Screwdriver
❑3mm Hex Wrench
❑Adjustable Wrenches (2)
❑Modeling Knife
❑(2) Wheel Pants
❑(2) Landing Gear Brackets
❑(2) Main Gear Wheels
❑(2) Threaded Axle Shafts
❑(6) M4 x 20mm Socket-Cap Screws
❑(6) M4 Flat Washers
❑(2) M8 Hex Nuts
❑(2) Wheel Collars with Grub Screws
❑(2) M3 x 12mm Wood Screws
❑(1) Hex Wrench
❑Electric Drill
❑5/64" (2mm) Drill Bit
❑Pencil
❑Airplane Stand
❑ The rudder is hinged using ve hinges. Notice that two hinges are
installed side-by-side at the bottom of the rudder.

Page 15
STEP 1: INSTALLING THE LANDING GEAR BRACKETS
❑Cut away the covering material from over the landing gear brackets
mounting plate in the bottom of the fuselage.
❑Install the two landing gear brackets, using six M4 x 20mm socket-cap
screws and six M4 at washers.
STEP 2: INSTALLING THE WHEEL PANTS
❑Slide one threaded axle shaft through the predrilled hole in one landing
gear bracket.
❑Partially slide one wheel pant, followed by one M8 hex nut and one main
gear wheel onto the threaded axle shaft.
❑While holding the wheel pant in position (the edges of the molded recess
in the side of the wheel pant should be parallel to the front and back edges
of the landing gear bracket), use two adjustable wrenches to rmly tighten
the threaded axle shaft and hex nut.
IMPORTANT Tighten the assembly rmly so that the wheel pant cannot
rotate under pressure.
❑ Install the wheel collar and tighten the grub screw rmly, using the hex
wrench provided.
❑Repeat the previous procedures to install the second wheel and wheel
pant assembly. Before installing the wood screw in the second wheel pant
assembly, double-check that both wheel pants are lined up with each other
when viewed from the side.
❑While holding the wheel pant aligned (the edges of the molded recess in
the side of the wheel pant should be parallel to the front and back edges of
the landing gear bracket), drill a 5/64" (2mm) diameter pilot hole through
the wheel pant, using the small predrilled hole in the landing gear bracket
as a guide.
❑Install and tighten one M3 x 12mm wood screw to lock the wheel pant
into place and keep it from rotating.

Page 16
ENGINE INSTALLATION
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑4mm Hex Wrench
❑8mm Nut Driver
❑(2) Adjustable Engine Mounting Beams
❑(4) M5 x 25mm Socket-Cap Screws
❑(4) M5 x 30mm Socket-Cap Screws
❑(8) M5 Flat Washers
❑(4) M5 Lock Nuts
❑(4) M5 Blind Nuts
❑Adjustable Wrench
❑Straight Edge Ruler
STEP 1: INSTALLING THE ENGINE MOUNTING BEAMS
IMPORTANT The following procedures outline the installation of a four-stroke engine. If you are installing a two-stroke engine,
the installation procedures are the same. The Magnum XL 1.80RFS engine is shown.
❑ Remove the mufer assembly from your engine, then install your spinner
backplate (not included) onto the crankshaft, using the propeller washer and
nut included with your engine.
❑Temporarily mount your engine onto the engine mounting beams, using
four M5 x 30mm socket-cap screws, four M5 at washers and four M5 lock
nuts.
PRO TIP Mount the engine as far forward as possible to ensure that the
engine mounting beams remain square.
❑ Line up the engine mounting beams with the precut slots in the rewall
and temporarily install the four M5 x 25mm socket-cap screws, four M5 at
washers and four M5 blind nuts.
❑Carefully center the engine mounting beams over the precut slots and
rmly tighten the four socket-cap screws to draw the blind nuts into the back
of the rewall.
STEP 2: ALIGNING THE ENGINE
❑Loosen the four socket-cap screws and lock nuts so that the engine can
be slid back and forth.
❑Measure the distance from the front of the engine mounting box to the
back of the spinner backplate. Adjust the depth of the engine so that the
measurement is 6" (152mm).
❑ When satised with the alignment, rmly tighten the four socket-cap screws and lock nuts.

Page 17
THROTTLE CONTROL SYSTEM INSTALLATION
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑5 Minute Epoxy
❑Thick C/A
❑# 1 Phillips Head Screwdriver
❑Wire Cutters
❑Needle Nose Pliers
❑Modeling Knife
❑(1) 14" (356mm) Pushrod Wire with Z-Bend
❑(1) Adjustable Pushrod Connector Assembly with Grub Screw
❑(1) Plywood Servo Tray (Throttle)
❑(1) Balsa Support Stick (Short)
❑(1) Hex Wrench
❑Electric Drill
❑1/16" (1.6mm) and 5/64" (2mm) Drill Bits
❑Straight Edge Ruler
❑Pencil
❑Airplane Stand
STEP 1: INSTALLING THE THROTTLE SERVO
❑ Install the rubber grommets and brass collets onto your throttle servo, making sure to install the collets with the anges toward
the bottom of the servo.
❑Install the throttle servo into the plywood servo tray, making sure to drill
1/16" (1.6mm) diameter pilot holes for the mounting screws.
IMPORTANT Note the orientation of both the servo tray and the servo.
When installed, the servo output shaft must be toward the back of the
fuselage.
❑ Test-t the servo tray into the fuselage, making sure that the tab at the
front of the servo tray ts into the notch in the forward bulkhead and that the
side of the servo tray ts down against the fuselage side doubler.
❑ When satised with the t, epoxy the servo tray into place.
❑After the epoxy sets up, glue the short balsa support stick to the top of
the servo tray and to the fuselage side.
STEP 2: INSTALLING THE THROTTLE PUSHROD WIRE
❑Remove the throttle arm from your engine and install the Z-Bend in the
pushrod wire into the outermost hole in the throttle arm.
☞You may need to enlarge the hole in your engine's throttle arm, using a
5/64" (2mm) diameter drill bit, to accommodate the pushrod wire.
Front
❑ Slide the pushrod wire through the predrilled holes in the rewall and fuselage
support bulkheads, then reinstall the throttle arm onto your engine.
❑Open and close the carburetor several times to ensure that the pushrod
wire does not bind. You may need to make a shallow bend or two in the
pushrod wire where it exits the rewall to prevent any binding that might
occur.

Page 18
STEP 3: INSTALLING THE ADJUSTABLE PUSHROD CONNECTOR
❑Enlarge the hole in the servo arm that is 9/16" (14mm) out from the center
of the servo horn, using a 5/64" (2mm) diameter drill bit.
❑Install the adjustable pushrod connector onto the servo arm, using two
at washers (one on top of the arm and one on the bottom) and the C-clip.
☞Depending on the thickness of your servo arm, you may need to use
only one at washer on the bottom of the servo arm.
❑Slide the adjustable pushrod connector assembly onto the pushrod wire,
then install the servo horn onto the servo, making sure that it's angled
approximately 30 degrees from center.
❑While holding the carburetor fully open (closed for two-stroke engines),
install and tighten the grub screw in the adjustable pushrod connector.
❑Connect your radio system and check that the throttle servo output shaft is rotating in the correct direction, then position the throttle
control stick and the throttle trim lever to their lowest positions.
❑Cut away the excess pushrod wire, then install and tighten the servo horn retaining screw to hold the servo horn securely to
the servo.
❑Open and close the throttle several times to ensure that the carburetor opens and closes completely. You may need to adjust your
transmitter EPA settings to achieve perfect settings.
❑Cut away all but one arm from a "4-point" servo horn.
FUEL TANK ASSEMBLY AND INSTALLATION
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑Silicon Sealant
❑# 2 Phillips Head Screwdriver
❑Modeling Knife
❑Scissors
❑Straight Edge Ruler
❑(1) 500cc Fuel Tank
❑(3) Aluminum Tubing
❑(1) Rubber Stopper
❑(1) Large Metal Plate
❑(1) Small Metal Plate
❑(1) Silicone Fuel Tubing with Clunk
❑(1) M3 x 18mm Machine Screw
❑Pencil
❑Airplane Stand
❑220 Grit Sandpaper with Sanding Block
❑Masking Tape

Page 19
STEP 1: ASSEMBLING THE RUBBER STOPPER
IMPORTANT Discard one of the longer aluminum tubes. It will not be used for our style of fuel tank setup.
❑Push the two aluminum tubes through the rubber stopper, then slide the
large diameter metal plate over the tubes at the front of the rubber stopper
and slide the small diameter metal plate over the tubes at the rear of the
rubber stopper. Adjust the tubes so that they both are 3/8" (10mm) out from
the front of the stopper assembly.
❑Secure one end of the silicone fuel tubing onto the end of the clunk.
❑Slide the silicone fuel tubing, with the clunk attached, onto the end of the
aluminum fuel pick-up tube (straight tube). Adjust the length of the silicone
tubing until the end of the clunk is 4" (102mm) back from the rear of the
stopper assembly.
❑Carefully bend the longer of the two aluminum tubes up at a shallow
angle, being careful not to kink the tubing as you bend it.
IMPORTANT When the stopper assembly is installed in the fuel tank,
the top of the vent tube (the tube you just bent) should rest just below the
top of the fuel tank.
STEP 2: INSTALLING THE STOPPER ASSEMBLY
❑With the stopper assembly installed, double-check to make sure that the clunk can move freely inside the fuel tank. Ideally, the
clunk should be about 1/4" (6mm) in front of the back of the fuel tank. This will ensure that the clunk can't get stuck in the fuel tank
during ight.
❑Carefully push the stopper assembly into the fuel tank and rotate it until
the aluminum vent tube rests just below the top of the fuel tank.
❑ When satised with the alignment, install and tighten the M3 x 18mm
machine screw until the rubber stopper expands and seals the fuel tank opening.
PRO TIP Holding the fuel tank up to a bright light will allow you to see
inside to double-check the correct position of the vent tube.
STEP 3: INSTALLING THE FUEL TANK
❑Cut two pieces of silicone fuel tubing (not included) to a length of 10"
(254mm) and install them to the aluminum tubes at the front of the fuel tank.
PRO TIP Mark the ends of the silicone tubing "vent" and "pick-up" so
you don't confuse them when it comes time to connect them to the engine
later on.

Page 20
❑Wrap the fuel tank in one layer of 1/4" (6mm) thick foam rubber, using
strips of masking tape to hold the foam rubber in place.
❑ Feed the ends of the fuel tubing through the predrilled hole in the rewall
and slide the fuel tank into position, making sure that the fuel tank is pushed
against the back of the rewall.
IMPORTANT When you slide the fuel tank into position, make sure that
the top of the fuel tank is toward the top of the fuselage.
❑ Double-check that the fuel tank is held rmly in place, then apply a thick layer of silicon sealant to the fuel tank opening (around
the fuel tubing) at the front of the rewall to prevent exhaust residue from getting inside the fuselage.
ELEVATOR CONTROL SYSTEM INSTALLATION
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
❑5 Minute Epoxy
❑Thin C/A
❑# 1 Phillips Head Screwdriver
❑Needle Nose Pliers
❑Modeling Knife
❑Electric Drill
❑1/16" (1.6mm) and 5/64" (2mm) Drill Bits
❑Straight Edge Ruler
❑(1) Split Elevator Pushrod Assembly
❑(1) Pushrod Support Plate
❑(2) Threaded Control Horns
❑(2) Control Horn Backplates
❑(2) Adjustable Control Horns
❑(2) Clevises
❑(1) Snap-Keeper
❑(6) M2 x 50mm Machine Screws
❑(1) Heat-Shrink Tubing
❑(1) Plywood Servo Tray (Elevator)
❑(2) Balsa Support Sticks (Long)
❑(4) M2 x 8mm Wood Screws
❑Pencil
❑Airplane Stand
❑Masking Tape
❑Epoxy Mixing Sticks
❑Epoxy Mixing Cups
❑Heat-Sealing Iron
❑Heat Gun
STEP 1: INSTALLING THE ELEVATOR SERVO
❑Install the rubber grommets and brass collets onto your elevator servo,
making sure to install the collets with the anges toward the bottom of the servo.
❑Install the elevator servo into the plywood servo tray, making sure to drill
1/16" (1.6mm) diameter pilot holes for the mounting screws.
IMPORTANT Note the orientation of both the servo tray and the servo.
When installed, the servo output shaft must be toward the back of the
fuselage.
IMPORTANT The elevator servo tray has oval lightening holes cut in it. The rudder servo tray has rectangular lightening holes.
Front