Stevens Aero Model 1928 Pietenpol SkyScout Manual

Wing Span: 48 inches | Wing Area: 425 square inches | Average Flying Weight: 245 ounces
Build Instructions - Version 1.24 (revised 03.19.2016)

WARRANTY
Stevens AeroModel guarantees this kit to be free from defects in both material and workmanship at the
date of purchase. This warranty does not cover any component parts damaged by use or modification.
In no case shall Stevens AeroModel’s liability exceed the original cost of the purchased kit. Further,
Stevens AeroModel reserves the right to change or modify this warranty without notice.
LIABILITY RELEASE
In that Stevens AeroModel has no control over the final assembly or material used for final assembly,
no liability shall be assumed nor accepted for any damage resulting from use by the user. By the act of
using the user-assembled product, the user accepts all resulting liability.
If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is
advised to return this kit immediately in new and unused condition to the place of purchase.
THIS PRODUCT IS NOT INTENDED FOR CHILDREN 12 YEARS OF AGE OR YOUNGER.
WARNING: This product may contain chemicals known to the state of California to cause cancer
and/or birth defects or other reproductive harm.
PRODUCT SUPPORT
This product has been engineered to function properly and perform as advertised, with the suggested
power system and supporting electronics as outlined within this product manual. Product support
cannot be provided, nor can Stevens AeroModel assist in determining the suitability or use of
electronics, hardware, or power systems not explicitly recommended by Stevens AeroModel.
For product assembly support, replacement parts, hardware, and electronics to complete this model,
please contact Stevens AeroModel at www.stevensaero.com.
Stevens AeroModel
26405 Judge Orr Rd., Colorado Springs, CO 80808 USA
719-387-4187 www.stevensaero.com
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 2

Project Checklist
Kit Contents
☐Laser-cut wood package, 21 Laser Cut Sheets (See inventory on following pages.)
☐1 - Scalloped turtle deck fairing, part “F27” (1/64 plywood)
2 - Pushrod tubing, .032 i.d. x 18 in. (.070 o.d. yellow nylon)
3 - Pushrod wire, .032 x 18 in.
☐Photo Illustrated instruction manual (No plan set is required to complete this model.)
☐Landing Gear and Empennage Template Sheet (11x17)
☐1 - Cowl (white styrene)
☐2 - Landing gear struts (Front and Rear), pre-bent
☐Long Hardware Bag (3 x 24 in.)
1 - Vintage tire material, 24 in. length 1/2 in. dia. rubber cord [*]
2 - Flying struts (front), laser-cut
2 - Flying struts (rear), laser-cut
2 - Servo wire paper guide tubes, 18 in. length
2 - 1/4 in. dia. x 24 in. length Balsa Dowel Stock (Leading Edge)
3 - 3/32 in. x 3/16 in. x 24 in. Balsa Stock (Fuselage Stringers)
☐Large Hardware Bag (4 x 6 in.)
1 - 1/4 in. x 4 in. Heat Shrink Tube [*]
1 - Basswood Elevator Joiner “E5” [*]
1 - 1 in. Length Silicone Fuel Tubing [4005]
1 - PTEG Laser Cut Windshield [*]
1 - Nylon Tail Skid (DUB853) [4023]
2 - 1/8 in. dia. x 2 in. length hardwood dowel [1017]
3 - CA Hinges [4024]
10 - Du-Bro Micro II Control Horns [4020]
☐Small Hardware Bag (2 x 3 in.)
2 - Hairpin Cotter Pins (98335A024) [4011]
2 - #4 Nylon Flat Washers [3018]
2 - 3/16 in. dia. Neo. Magnets [4014]
2 - (.188) 3/16 in x (1.50) 1-1/2 in. Brass Tube (Axles) [5001]
2 - (.219) 7/32 in. x (1.25) 1-1/8 in. Brass Tube (Wheel Bearings) [5003]
4 - (.219) 7/32 in. x (.156) 5/32 in. Brass Tube (Wheel Collars) [5002]
4 - Mini EZ Connectors (DUB845) [4021]
4 - #0 x 3/16 in. Screws [3010]
4 - 4-40 x 3/8 in. Machine Screws [3007]
4 - 4-40 Blind Nuts [3001]
4 - 1/16 in. x 1/4 in. Aluminum Tube [2010]
4 - 1/8 in. x 7/16 in. Aluminum Tube [2009]
8 - Steel Landing Gear Straps (DUB158) [3017]
12 - Micro EZ Links (DUB849) [4017]
16 - #2 x 1/4 in. Screws [3011]
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 3

Required Electronics (Available at StevensAero.com)
☐4-6 Channel radio and micro receiver.
☐4 - HI-TEC HS-40 servos (2 Ailerons | Rudder | Elevator)
☐2 - 24 in. servo extensions
☐SA Sport Park BL450 2217-9 Motor [SUPA2217-9] and APC 9 x 4.7 SF Propeller [APC09047]
☐Talon 25 ESC (Thunderbird 18 also suitable)
☐3S 1300 mAh 11.1V LiPo Battery
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 4
Required Building Supplies and Tools
☐1/2 oz. Thin CA Glue
☐1 oz. Medium CA Glue
☐1/2 oz. Thick CA Glue
☐CA glue Accelerator
☐3/4 x 12 in. length Adhesive Backed Velcro
☐Silver Solder and Flux [SBSK]
☐Balsa filler
☐Hobby Knife with supply of #11 blades
☐Sanding block with 400 and 600 grit paper
☐Heat Gun and Covering Iron
☐Small Needle Nose Pliers
☐Pin Vise with 1/32 in. drill bit.
☐1/8 in. dia. drill bit.
☐3/4 in. wide clear tape
☐Low Tack Painters Masking Tape
☐1-2 Rolls AeroLITE (solite)
☐1 Roll AeroTRIM (solartrim)
Suggested Building Supplies
☐CA glue de-bonder
☐Long sanding bar

Laser Cut Parts Inventory
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 5

Laser Cut Parts Inventory
Build Instructions
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Laser Cut Parts Inventory
Build Instructions
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Laser Cut Parts Inventory
Build Instructions
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General Assembly Instructions
Thank you, for purchasing this Stevens AeroModel Sky Scout™. A design inspired by the joy of flying.
This model has been developed and manufactured using state of the art CAD/CAM systems and features
a unique interlocking construction process that, when compared to traditional methods found in other
model aircraft kits, save countless hours of measuring, cutting, sanding, and fitting. We are certain that
you’ll find our kit to offer a truly exceptional build experience. As this kit is recommended for the novice
model builder and “pilot”; we invite absolute beginners to correspond with us, or to seek the help of
another seasoned builder. At any time should one run across a term or technique that is foreign please
don’t hesitate to contact our staff with your questions.
READ THIS
Please READ and RE-READ these instructions along with any other included documentation prior to
starting your build and or contacting our staff for builder support.
Pre-sanding
Do not skip this step. Prior to removing any parts from the laser cut sheet wood use a sanding block
loaded with 250-400 grit paper and lightly sand the back side of each sheet of wood. This step removes
any residue produced as a result of the laser cutting process and, as we have found that most stock wood
sizes run several thousandths of an inch over sized, slightly reduces the thickness of each sheet.
Leave your pre-sanded parts in the sheet until required in the assembly process.
Protecting your worktable
Use the poly tube that this kit was shipped in as a non-stick barrier between your worktable and the
product assembly. Promptly clean up any epoxy spills with rubbing alcohol and a disposable towel.
Bonding the assembly
As this product tabs, notches, and otherwise interlocks like a 3D puzzle we suggest that when fitting parts
you dry fit (use no glue) the parts together first. It’s advised to work 1-2 steps ahead in the instructions
using this dry-fit technique which allows ample opportunity to inspect the fit and location of assembled
components and realizes a benefit as each successive part contributes to pulling the entire assembly
square. Once you arrive at the end of a major assembly step(s) square your work on top of a flat building
table and revisit the dry fit joints with glue. Using the dry-fit process you’ll be able to recover from a minor
build mistake and will ultimately end up with a more square and true assembly.
Unless otherwise noted in the instructions, always use medium CA glue for bonding parts.
Never force the fit!
Remember this is a precision cut kit our machines cut to within 5 thousandth of an inch in accuracy. Yet
the wood stock supplied by the mill may vary in thickness by up to 20 thousandths. This variance in the
wood stock can cause some tabs/notches to fit very tight. With this in mind, should you find a joint or two
to fit rather snug consider lightly sanding a tight fitting tab rather than crushing and forcing your parts
together. You’ll break fewer parts in assembly and will end up with a more square and true assembly.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 9

Scale Notes
The Pietenpol Sky Scout was designed by Bernard H. Pietenpol in the late 1920’s as an easy and
inexpensive to construct homebuilt aircraft for the average guy. Plans were published in Modern
Mechanics and Inventions in 1932, and reprinted in their annual Flying Manual in 1933, and are still
available from the Pietenpol family. This model was designed using the original plans as published in
the 1933 Flying Manual.
Since the Sky Scout depended on the builder’s ability to scrounge parts and materials, no two were
built exactly the same. Variations in the type of engine, cowling, landing gear configuration, etc. were
the norm.
We designed our model with simplified scale details, leaving plenty of room for variation and the taste
of the individual modeler. Excellent scale detail reference material can be found in the afore
mentioned 1933 Flying Manual, still published by the Experimental Aircraft Association, and on
several sites on the internet, including the official Pietenpol site and many others dedicated to this
particular aircraft.
Additional details you might want to add are: a shock strut or spreader bar for the landing gear, wood
fairings for the landing gear struts, wire bracing between the flying and cabane struts, a pull-pull
control system with scale control horns on the control surfaces, and cockpit coaming. Details
specific to a particular aircraft, such as wheel type, engine and cowling, windshield, tail skid type,
color scheme, etc. may also be added.
Have fun researching your model. Changes to the details should be planned before construction
begins. Read this manual thoroughly before making any changes. Or simply build it as we represent
it here and enjoy a simple build and many hours of pleasurable flying.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 10

Definitions of Construction Terminology:
Fit - Assemble parts together “dry”, using no glue, as friction between the fit parts alone should retain
the pieces within the assembly.
Tack / Tack Glue - Use medium CA glue administered sparingly through use of a fine gauge glue tip
to place a small dot of glue to retain fit parts within assembly (non-permanent easily separated).
Bond - Unless otherwise specified, use thin or medium CA glue and a fine applicator tip to thoroughly
glue parts within assembly along all mating surfaces.
Fillet - Use medium or thick CA glue administered through a fine to medium gauge glue tip to build up
a trough of glue along adjoining parts. The easiest way to understand what a proper glue fillet looks
like is to go and have a look at the caulk that seals your bathroom shower or tub to the walls and
floor; your glue fillet should resemble this caulking. Fillets are typically used in high stress locations
such as motor or landing gear assemblies.
Harden - When requested to harden a wooden part with glue we are suggesting that a thin viscosity
CA glue is applied liberally to an area (usually a mounting hole for a screw, exit point for landing gear,
or some other part that needs additional strength), allowed to wick into the fibers and pores of the
material, and cure.
Proper Use of Thin, Medium, and Thick Cyanoacrylate (CA) Glue
Follow the general tips given below for determining the proper use of the various viscosities and
varieties of CA glue as they relate to the construction of balsa and hardwood models. We suggest
the use of a “Top Shelf” CA glue such as Zap brand glues as they have proven more consistent in
formulation, working time, and strength than the wide array of budget glue products.
Thin - This watery form of CA glue readily wicks into porous materials (such as balsa or ply woods)
and cures/sets rapidly (usually within 1-3 seconds of application). A fine gauge glue tip is mandatory
in regulating the flow of this CA glue from bottle to model. Thin CA glue is excellent at rapidly bonding
tight fitting joints and hardening areas of balsa wood. Thin CA glue is not suggested for bonding
parts that have minor gaps or spans to bridge, wrapped parts (such as sheeting), or when additional
working time is required. Generally an accelerator is not used with thin CA glue.
Medium - A general purpose glue with good gap filling properties, fair wicking ability, and intermediate
working times (5-10 seconds). Medium CA glue is an excellent glue for temporarily bonding or
tacking parts together, filling minor gaps, bonding plywoods, creating fillets, and reinforcing high
stress areas of the model such as spars and motor mounts. A fine gauge applicator tip is
recommended to precisely apply medium CA glue. Accelerators are typically not used with medium
CA glue unless repairing a previously bonded joint.
Thick - Generally not required for construction of our model kits, thick CA glue gives the user extra
working time (10-20 seconds) to properly locate and apply sheeting, build larger fillets, or fill large
gaps. Accelerators are generally preferred when making repairs with thick CA glue.
Accelerator - Commonly referred to as “Kicker” and available in pump and aerosol configurations.
Good for setting glue rapidly when making repairs or to decrease the working time of Medium and
Thick CA’s. An accelerated glue joint is typically weaker than if the glue was left to cure normally.
Odorless / Foam Safe - Often available in Medium and Thick formulas, this glue sets very slowly and
does not produce as many fumes when curing. Good for use in place of normal CA glue when the
user is sensitive to the fumes or has a CA glue allergy. Accelerators are almost mandatory to
decrease the working time of this product.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 11

Empennage
☐Begin horizontal stabilizer by fitting H1 and
H2 together.
☐Fit two H3’s to the ends of H1 as illustrated.
☐Fit H4 to assembly centered by H2 and
spanning both H3 parts.
☐Fit parts HS where indicated. Bond assembly
over a flat work surface using thin CA glue.
☐☐ Build one elevator half at a time. Fit part
E1 to E2.
☐☐ Fit E3 to E1.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 12
H1
H2
H1
H3
H3
H2
H1
H3
H3
H4
HS
E1
E2
E1
E3

Empennage Cont.
☐☐ Fit E4 spanning E2 and E3.
☐☐ Fit parts E where indicated. Bond
assembly using thin CA glue. Repeat
previous steps marked ☐☐.
☐Using a straight edge as a guide, join the two
halves of the elevator with the hardwood part
E5. Bond with medium CA.
☐Begin vertical stabilizer by fitting together
parts VS1 and VS2.
☐Fit part VS3 to VS1 and VS2.
☐Fit parts VS where indicated. Bond assembly
over a flat work surface using thin CA glue.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 13
E2
E4
E3
E
VS1
VS2
VS1
VS2
VS3
VS
E5

Empennage Cont.
☐Begin rudder by fitting parts R1 and R2
together.
☐Fit R3 to R1.
☐Fit R4 spanning R2 and R3.
☐Fit parts R where indicated. Bond assembly
over a flat work surface using thin CA glue.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 14
R2
R1
R1 R3
R2
R3
R4
R

Wing Construction
☐Build front spar from parts W1a, W1b, and
W1c. Fit W1a to W1b at dove tail joint.
Fit W1c to W1b. Now, align front spar along a
straight edge or ruler and bond with thin CA.
☐Build rear spar from parts W2a, W2b, and
W2c. Fit and bond W2a to W2b at dove tail.
Fit W2c to W2b. Now, align rear spar along a
straight edge or ruler and bond with thin CA.
☐Build trailing edge from parts W3a, W3b, and
W3c. Fit W3a to W3b at dove tail joint.
Fit W3c to W3b. Now, align parts along a
straight edge or ruler and bond with thin CA.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 15
W1a
W1b
W1b
W1c
W2a
W2b
W2b
W2c
W3a
W3b
W3b
W3c

Wing Construction Cont.
☐Fit center rib W4 to the center of the front
spar W1. Tack glue with thin CA.
☐Fit rear spar W2 under rib W4 and tack glue
with thin CA.
☐Fit and tack glue trailing edge W3 to rear of
rib W4.
☐Fit two ribs W5 on each side of center rib W4.
Tack glue with thin CA.
☐Fit rib brace W6 to slot in rib W5. W6 should
rest flush against the front spar W1.
☐Fit sub-rib W7 to front spar W1 and brace W6.
Bond with medium CA.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 16
W4
W1
W4
W2
W4
W3
W4
W5
W5
W5 W1
W6
W6W7
W1

Wing Construction Cont.
☐Fit and bond remaining W6 and W7 to the
opposite rib W5.
☐Fit and tack glue ribs, on to both left and right
of wing center beginning with partial rib W8.
☐Partial rib W9.
☐Full rib W10 (left W10 not shown).
☐Partial rib W11 (left W11 not shown).
☐Partial rib W12 (left W12 not shown).
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 17
W6 W1
W7
W5
W8
W8
W9
W9
W10
W11
W12
Left
Right
Center

Wing Construction Cont.
☐Full rib W13 (left W13 not shown).
☐Full rib W14 (left W14 not shown).
☐Partial rib W15 (left W15 not shown).
☐Partial rib W16 (left W16 not shown).
☐Full rib W17 (left W17 not shown). Do not
install the remaining ribs at this time.
☐Install blind nuts, for cabane attach points,
into hardwood parts W18 and W19. Using a
small hammer, seat them firmly within the
etched circles. Bond them to the wood with
medium CA around the edge of the flanges.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 18
W13
W14
W15
W16
W17
W18
W19

Wing Construction Cont.
☐Fit W18 across rib W4 and ribs W5, flush
against the front spar W1. Bond with medium
CA. Create fillets of glue along all inside
mating surface for extra strength.
☐In the same manner as W18 instruction, fit
and bond hardwood part W19 to assembly.
☐Fit and bond part W20 spanning rib W4 and
ribs W5, and against part W19.
☐☐ Fit and bond hardwood parts W21,
spanning ribs W13 and W14, and against
the spars. The holes in W21 should be
on the outboard end of the part and
closest to the spar. Build up a fillet of
glue around all mating surfaces.
☐☐ Fit W22 between ribs W5 and W10. The
hole in W22 should fall in line with the
holes in the ribs. Ensure arrows on the
diagonal braces point up and toward the
front spar. DO NOT GLUE!
☐☐ In the same way, fit W23 between ribs
W10 and W13. DO NOT GLUE!
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 19
W18
W5 W4
W5
Bottom View
W1
W19
Bottom View
Rear Spar W2
Bottom View
W19
W20
W4
W5
W5
Bottom View
W21
W13
W14
Wing Tip
W22
W5
W10
W23
W10
W13
W5
W5

Wing Construction Cont.
☐☐ Fit W24 between rib W14 and rib W17.
DO NOT GLUE!
☐Repeat previous ☐☐steps for opposite side
of wing assembly.
☐Cut both paper tubes to 17 in. long.
☐Beginning at rib W17, slide tubes through the
holes in the ribs and diagonals.
☐When in position, the tubes should extend
about 1/8 in. beyond rib W17.
☐The other end of the tubes should extend
about 1/2 in. beyond ribs W5.
☐Square the wing on a flat surface and check
the alignment of all parts.
Build Instructions
SkyScout 480 - Build Instructions © 2010 Stevens AeroModel, all rights reserved.!Page 20
W24
W14
W17
W17
W17
1/8 in.
W5 W5
1/2 in.