Stevens Aero Model Ace 100 User manual

Wing Span: 24 inches | Wing Area: 100 square inches | Average Flying Weight: 2.25 ounces
Build Instructions - Version 1.18 (revised 03.30.2017)
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100

Build Instructions
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Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 2
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
Ace (100) - Kit Inventory
☐Laser-cut wood, 10 sheets (See Sheet Wood Inventory, page 5)
☐Illustrated Build Instructions
☐Plan Set, 2 sheets, 11 in. x 17 in.
Taped to back of wood brick:
☐1 Landing gear, wire, .032 in. x 12 in.
☐2 Push rods, wire, .015 in. x 18 in.
Hardware Bag:
☐1 Heat shrink tube, 1 1/2 in. x 1/16 in.
☐1 Delrin receiver clip
☐1 Pair plastic wheels (SIGSH450)
Background
The Ace (100) is a pint-sized package, bursting at the seams with nostalgic charm. This compact 100
square-inch radio control model is designed to use ParkZone PKZ3352 ultra-micro electronics. The Ace
can be flown indoors, at the local gymnasium, or hop from thermal-to-thermal outdoors in late evening lift.
The nostalgic lines of the Ace are presented here with a strong nod to Henry Struck and his 1940’s
vintage New Ruler and American Ace free flight designs. The Ace design was directly inspired by this
iconic model, while reminiscent of those bygone years, our kit offers a modern design that builds trouble-
free and quickly, thanks to innovative design processes pioneered by Stevens AeroModel.!
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 3

Build Instructions
Suggested Items to Complete this Model
Many of the suggested items listed below are available at your local hobby shop. For your convenience,
Stevens AeroModel stocks all the power system components and most of the building supplies required
to complete this kit. If you have difficulties sourcing any of these items locally, please visit our website,
stevensaero.com to purchase the items necessary to complete your model.
Required Electronics
☐RC transmitter with at least 3 channels
☐Receiver/ESC/Servo brick (PKZ3352 or SPMAR6410)*
☐Motor/Gearbox (PKZ3624)
☐Propeller, 130mm x 70mm (EFL9051)
☐LiPo battery, 120 - 160 mAh 3.7V
*SPMAR6410 may be used with computer radio.
Covering Film Requirements
While any high-quality covering film may be used to finish this model, superior results will be achieved by
using genuine AeroLITE brand covering film, available exclusively from Stevens AeroModel. The lower
working temperature and light weight of AeroLITE are especially desirable for this type of model.
AeroLITE is one-third the weight of typical model covering films, and will present a significant weight
savings when applied to this model.
☐2-3 PatchPaks AeroLITE base color
☐1 - PatchPak AeroLITE trim color or 1 roll AeroTRIMTM (pressure-sensitive adhesive trim)
☐1 - Optional black vinyl markings set to complete the model as illustrated (SAP-ACE100/DECAL)
Sealing Bare Wood
While not required, it is suggested that a high-quality clear lacquer be used to protect and seal any
unfinished wood. One single light coat of clear lacquer should be sufficient to protect the model from
moisture, without adding significantly to the model’s final flying weight.
Many parts of this model may be colored using a lacquer-based spray paint. Listed below are some of
the products we have used on our models. Please feel free to use whatever products you prefer.
☐DEFT clear lacquer-based sealant (available at most hardware stores)
☐Design Master Color Tool, lacquer-based spray paint (available at most arts and crafts stores)!
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 4
Required Building Supplies and Tools
☐CA glue, medium, 1/4 oz (PAAPT04)
☐CA glue, thin, 1/4 oz (PAAPT10)
☐CA glue applicator tips (PAAPT21)
☐CA glue accelerator (PAAPT15)
☐Hobby knife with supply of #11 blades
☐Sanding block with 120 and 240 grit paper
Building Supplies and Tools
☐Covering iron and heat gun
☐Needle nose pliers, small
☐Clear tape, 1/2 in. (DUB916)
☐Velcro for mounting battery (PKZ1039)
☐Masking tape (low-tack blue painters’ tape)
☐AeroLITETM covering film
Optional Building Supplies and Tools
☐Balsa filler (HCAR3401)
☐Modeling clay (ballast)
☐CA glue de-bonder (PAAPT16)
☐Required Building Supplies
☐
☐Clear lacquer-based sealant (DEFT®)
☐Lacquer-based spray paint (Design
Master®)

Build Instructions
Sheet Wood Inventory (1 of 1)
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Build Instructions
Builder’s Notes
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Build Instructions
General Assembly Instructions
Thank you for purchasing the Ace 100 from Stevens AeroModel.
This model has been developed and manufactured using state-of-the-art CAD/CAM systems. Our kits
feature a unique interlocking construction process, that when compared to traditional building methods,
saves 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 beginners who have
purchased this kit to seek the help of an experienced builder and pilot. If at any time during the assembly
of this kit, should you run across a term or technique that is foreign to you, please contact our staff with
your questions.
IMPORTANT!
Please READ and RE-READ these build instructions along with any other included documentation before
starting your build and/or contacting our staff for builder support.
Pre-Sanding
DO NOT SKIP THIS STEP. Before removing any parts from the laser-cut sheet wood, use a sanding
block loaded with 120 - 240 grit sandpaper and lightly sand the back side of each wood sheet. This step
removes any residue produced as a result of the laser cutting process. We have found that most stock
wood sizes run several thousandths of an inch oversized. This step also slightly reduces the thickness of
each sheet of wood. Leave all parts in the sheet wood until required for assembly.
Protecting Your Work Surface
Use the poly tube that this kit was shipped in as a nonstick barrier between your work surface and the
product assembly.
Bonding the Assembly
This product’s tabs and notches interlock like a 3D puzzle. We strongly suggest that when fitting parts,
you dry fit (use no glue) the parts together first. It is advised to work 1 - 2 steps ahead in the instructions,
using this dry-fit technique. This allows the opportunity to inspect the fit and location of assembled
components, and shows the benefits of our construction technique. As each successive part is added, it
contributes to pulling the entire assembly square. Once you arrive at the end of a major assembly
sequence, square your work on a flat work surface and bond 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 square and
true assembly.
Unless otherwise noted in the instructions, we find it easier to “tack glue” parts (temporarily bonding parts
in assemblies, using a small dot of glue). When using medium CA glue, apply with a fine-tip CA glue
applicator. Never bond painted or covered assemblies with CA, as it can destroy the finish of a beautifully
prepared model.
Never Force the Fit!
This is a precision laser-cut kit. Our lasers cut to within 5 thousandths of an inch in accuracy. Yet the
wood stock supplied to us by the mill may vary in thickness by up to 20 thousandths. This variance in the
wood stock can cause some tabs and notches to fit very tightly. With this in mind, consider lightly sanding
or lightly pinching a tight-fitting tab, rather than forcing the parts together. You will break fewer parts in
assembly, and end up with a square and true airframe.
Manual Updates
Please check our website for updates to these instructions before starting the build. To obtain downloads
and updates to this model aircraft kit, please visit the product page at stevensaero.com
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 7

Build Instructions
Fuselage
Fuselage parts are designated with the letter “F” followed by a number. Parts have been numbered so
that the fuselage assembly follows a sequential order: F1 to F32.
Note: When initially bonding parts, use a single, small drop of medium CA glue, applied sparingly with a
CA glue applicator tip to “tack glue” the part in place. Should you commit an error in assembly, it will be
easier to recover from the mistake and remove or correct the part in error, if you do not soak the assembly
with glue after each step! This method of assembly will allow our interlocking design to do its job.
As each successive part is installed within the fuselage, it will help pull the entire structure square and
true. When a major assembly is completed, revisit all joints and bond completely. Do not use excessive
amounts of glue, as this only adds weight to the model.
1. Central Crutch - Lay F1a (sheet 01/10, 1/16 in. balsa) on the work surface with the etched
side facing up. Fit and bond F1b (sheet 01/10, 1/16 in. balsa) to the rear of F1a.
2. Pylon Pocket: Lay both F2’s (sheet 02/10, 1/16 in. balsa) on the work surface with the
etched sides facing up. Fit and bond one F3 (sheet 01/10, 1/16 in. balsa) to the slot in the
center of each F2.
3. Fit the F2/F3 assemblies to the slots in the front portion of F1, oriented so that the arrows at
the front of each F2 point to the front of F1. Do not bond!
4. Slide F4 (sheet 03/10, 1/16 in. balsa) between the F2’s oriented so that the arrow at the
front of F4 points toward the front of F1/F2. Tip: Use a wide length of 1/16 in. thick balsa,
as a push stick, to reach within the saddle cut at F4 and assist in seating this part between
F2 and flush with F1. Do not bond!
5. Fit former F5 (sheet 01/10, 1/16 in. balsa) to the slots in F1 at the rear of the pylon pocket,
and to the tabs at the rear of F2/F4.
6. Fit former F6 (sheet 02/10, 1/16 in. balsa) to the front of the assembly. Bond all parts with
CA. Make sure that no glue enters the pylon pocket itself!
7. Turn the assembly up side down. Fit and tack glue former F7 (sheet 02/10, 1/16 in. balsa)
to the slots in F1 immediately below former F5.
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Build Instructions
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 9
Step 1
Step 2
Step 3
Step 4
Step 7
Step 6
Step 5
Step 4 Cont.
F1a
Bottom View
F1b
F2
F1
F4
Flush
F5
F6
F7
F2
F3
F3
F2
F2
Flush
Rear View
F2
F1
Top
F1
Front

Build Instructions
Fuselage (continued)
8. Receiver Tray: Lay F8 (sheet 03/10, 1/16 in. balsa) on the work surface with the etched side
facing up. Fit the nylon receiver clip found in your hardware bag to F9 and F10, then fit and
bond the receiver tray to the four slots in the middle of F8. Orient the tray so that the long
arm of the clip is toward the front (tapered end) of F8.
9. Turn the crutch assembly up side down and fit F8 to the bottom of formers F6 and F7,
oriented so that the receiver tray is on the bottom of the model.
10. Turn the assembly right side up. Fit and tack glue former F11 (sheet 02/10, 1/16 in. balsa)
to the slots in F8 forward of former F6.
11. Fit and bond the nose spine F12 (sheet 03/10, 1/16 in. balsa) to formers F6 and F11,
oriented so that the long tab at one end of F12 points forward.
12. Motor Mount - Lay the motor mount plate F13 (sheet 09/10, 1/32 in. ply) on the work
surface with the side etched ‘Top’ facing up. fit and bond two F14’s (sheet 09/10, 1/32 in.
ply) to the top of F13.
13. Slide former F15 (sheet 10/10, 1/16 in. ply) onto the long tabs on the front of the two F14’s,
and the short tabs on the front of F13.
14. Fit the motor mount assembly to the long tab at the front of F12, and the short tabs at the
front of F8. The tab at the rear of F13 will fit in the recess in the top of the opening in former
F11. Bond with CA.
15. Fuselage Sides - Assemble the fuselage sides by laying F16a (sheet 01/10, 1/16 in. balsa)
on the work surface, then fitting and bonding F16b and F16c (sheet 01/10, 1/16 in. balsa) in
place, using CA.
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Build Instructions
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 11
Step 8
Step 9
Step 10
Step 11
Step 15
Step 14
Step 13
Step 12
F9
Bottom View
F8
F11
F12
F13
Top
F15
Recess
F16a
F16b
F8
F10
Long Arm
F7
F6
Receiver
Tray
F6
F11
F6
F14
F14
F16c
Top View
F15
F12
F11
F13
F14
F14

Build Instructions
Fuselage (continued)
16. Fit a fuselage side to each side of the front of the central crutch. Tack glue the fuselage
sides to the motor mount F13, the front portion of F8, and formers F6, F11, and F15.
17. Pull the sides together and tack glue to F1, the rear portion of F8, and formers F6 and F7.
18. Turn the assembly up side down and fit former F17 Sheet 02/10, 1/16 in. balsa) to the slots
in crosspiece F1b. Pull the sides together, and bond to the rest of F1 and former F17.
19. Fit the stabilizer saddle F18 (sheet 01/10, 1/16 in. balsa) to the rear of the fuselage sides,
directly behind F1. Square the assembly on a flat surface, and bond all parts together with
CA.
20. Landing Gear Pocket - Turn the assembly up side down. Fit part F19 (sheet 09/10, 1/32
in. ply) into the angled notches in the fuselage sides, and the pair of slots in F8. The
notches in the fuselage sides are oversized to accommodate the other parts of the landing
gear pocket. F19 will occupy the front portion of the notches. Do not bond.
21. Fit F20 (sheet 09/10, 1/32 in. ply) in the same notches in the fuselage side, flush against the
rear of F19. Do not bond.
22. Fit F21 (sheet 09/10, 1/32 in. ply) in the same notches, and the single slot in F8,
immediately behind F20. Make sure that all three parts are fully seated, then bond them
together and to the fuselage assembly with CA. Make sure that no glue enters the landing
gear pocket.
23. Fuselage Bottom - Lay F22a (sheet 03/10, 1/16 in. balsa) on the work surface, then fit and
bond F22b and F22c (sheet 02/10, 1/16 in. balsa) in place using CA.
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Build Instructions
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 13
Step 16
Step 17
Step 18
Step 19
Step 23
Step 22
Step 21
Step 20
F16
Bottom View
Bottom View
Bottom View
Bottom View
F16
F17
F18
F19
F20
F21
F22a
F8
F11
F6
F15
F22b
F22c
F13
F7
F6
F1
F8

Build Instructions
Fuselage (continued)
24. Fit F22 to the bottom of the fuselage assembly. Bond F22 where it meets the fuselage
sides, F21 of the landing gear pocket, and formers F7 and F17, with CA.
25. Fit and bond F23 (sheet 01/10, 1/16 in. balsa) to the fuselage bottom, forward of the landing
gear pocket.
26. Nose - Slide F24 (sheet 08/10, 1/8 in. balsa) onto the long tabs on F12 and both F14’s until
it is flush against the front face of former F15. Bond with CA.
27. Just as in step 26 above, slide F25 and F26a (sheet 08/10, 1/8 in. balsa) onto the tabs,
bonding with CA. Remove the tabs on each side of F26a.
28. Position F26b (sheet 08/10, 1/8 in. balsa) over F26a, aligning the edges of part F26b with
the edges of part F26a. Bond F26b to F26a, then remove the tabs on F26b.
29. Upper Fuselage - Fit former F27 (sheet 01/10, 1/16 in. balsa) to the two slots just in front of
the large opening in the rear of F1.
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Build Instructions
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 15
Step 24
Step 24 Cont.
Step 25
Step 26
Step 29
Step 28
Step 27 Cont.
Step 27
F22
Bottom View
Bottom View
Bottom View
Bond
F23
F24
F26a
Remove
Tabs
F26b
F27
Bond
Bond
Bond
F25
Remove
Tabs
F7
F21
F17

Build Instructions
Fuselage (continued)
30. Fit former F28 to (sheet 01/10, 1/16 in. balsa) the single slot in F1 immediately behind
former F27. Make sure that both formers are perpendicular to F1, then bond them together
and to F1 with CA.
31. Fit and bond former F29 (sheet 01/10, 1/16 in. balsa) to the slots in crosspiece F1b.
32. Fit and bond former F30 (sheet 01/10, 1/16 in. balsa) to the single slot at the front of F18.
33. Fit the front (wide) end of F31 (sheet 03/10, 1/16 in. balsa) to the recess in the top of former
F28. Make sure that F31 is parallel to F1 and that F31 does not extend forward of F28
(interfering with the later fitting of the cockpit sheeting over former F27 – see “Step 34”).
Bond F31 to F28 – allow time for the glue to cure. Bend F31 down until it rests in the
recesses in the top of formers F29 and F30 – bond with CA.
34. Lightly spray one side of the cockpit sheeting F32 (sheet 01/10, 1/16 in. balsa) with glass
cleaner and allow it to soak in for a few seconds. Wrap F32 – moist side out – around
formers F5 and F27. The notches at the front of F32 will line up with the notches in former
F5 and the split end of F32 will come together centered at the top of F27. Hold F32 in place
with low tack masking tape until it is completely dry. When F32 is dry, remove the tape and
bond it to the fuselage assembly with CA.
35. Using 3/32 in. square strip stock (sheet 05/10) cut and fit two stringers for each side of the
turtle deck at the rear of the fuselage. The stringers will fit into the notches on each side of
formers F28 and F29, then lie flat on each side of F31 against the front of former F30.
Bond with CA.
36. Using 3/32 in. square strip stock (sheet 05/10) cut and fit two stringers for each side of the
nose of the model. The stringers will fit in the notches in formers F15, F11, F6, F3, and end
in the pockets created by former F5 and the cockpit sheeting F32. Bond with CA.
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Build Instructions
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 17
Step 30
Step 31
Step 32
Step 33
Step 36 Cont.
Step 36
Step 35
Step 34
F28
Rear View
F27
F29
F30
F31
F32
Stringers
Stringers
Stringers
Stringers

Build Instructions
Fuselage (continued)
37. Sanding - Using a sanding block loaded with 120/240 grit paper, sand the nose to match
the contours shown on the 11x17 detail sheet.
38. Sand the corners off of the rear stringers so that the covering material will lie in a smooth
arc. Leave F31 flat. Lightly sand the rest of the fuselage, removing any excess glue and
smoothing the joints between parts.
Set the completed fuselage aside until needed in the Covering steps.
Tail Surfaces
39. Build the vertical stabilizer and rudder from parts V1 through V6, and R1 through R5 (sheet
05/10, 3/32 in. balsa), over the plan on the detail sheet, and bond with CA.
40. Lay the rudder on the work surface with the left side facing up and the leading edge aligned
with the edge of the work surface. Using a sanding block or sanding stick, sand a 45
degree bevel along the left side of the leading edge of the rudder.
41. Build the horizontal stabilizer and elevator from parts H1 through H5 and E1 through E5
(sheet 07/10, 3/32 in. balsa) over the plan on the detail sheet., and bond with CA.
42. Lay the elevator on the work surface with the etched side facing down, and the leading
edge aligned with the edge of the work surface. Using a sanding block or sanding stick,
sand a 45 degree bevel along the leading edge of the elevator.
Lightly sand the completed tail surfaces, removing any excess glue and smoothing the
joints between parts. Set the surfaces aside until needed in the Covering steps.
Pylon
43. Lay P1a and P1b (sheet 07/10, 3/32 in. balsa) on the work surface with the etched side
facing up. Fit P1a to P1b and bond with CA.
44. Position P2 (sheet 09/10, 1/32 in. ply) between the etched lines and the edges of P1. Bond
with CA.
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Build Instructions
Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page 19
Step 37
Step 38
Step 39
Step 40
Step 44
Step 43
Step 42
Step 41
45 deg.
P1a
P2
45 deg.
P1b
Etched
Lines

Build Instructions
Pylon (continued)
45. Turn P1 up side down so that the P2’s are underneath. Fit P3 (sheet 10/10, 1/16 in. ply)
into the slots down the center of P1. Make sure that P3 is perpendicular to P1, then bond
with CA.
46. Assemble the pylon sides from parts P4a and P4b (sheet 07/10, 3/32 in. balsa) and bond
with CA.
47. Fit the completed P4’s to each side of the pylon, oriented so that the arrow at the front of
the P4’s points in the same direction as the arrow at the front of P3. Bond with CA.
Sand the front and rear of the P4’s to round into the front and rear of P3. Set the completed
pylon aside until needed in the Covering steps.
Wing
Wing parts are designated with the letter “W” followed by a number. Parts have been numbered so that
the wing assembly follows a sequential order: W1 to W22.
48. Inner Wing Panels - Fit ribs W2 (sheet 06/10, 3/32 in. balsa), W4 (sheet 06/10, 3/32 in.
balsa), and W3 (sheet 04/10, 1/16 in. balsa) to the spar W1 (sheet 03/10, 1/16 in. balsa),
with the etched side of the spar facing to the rear of the ribs. Refer to the plan on the detail
sheet for the correct location of each rib.
49. Fit one trailing edge W5 (sheet 05/10, 3/32 in. balsa) to each side of the wing panel, with
the arrow at the inner end of W5 pointing toward ribs W2. Tack glue W5 to ribs W2, W3,
and W4.
50. Fit one W6 (sheet 05/10, 3/32 in. balsa) to the outside of ribs W2, bonding them to the
trailing edge, spar, and ribs W2.
51. Fit and tack glue one leading edge web W7 (sheet 06/10, 3/32 in. balsa) to the front of each
wing panel, oriented so that the arrow at the inner end of W7 points toward ribs W2.
52. Fit and tack glue the leading edge W8 (sheet 05/10, 3/32 in. balsa) to the front of each W7,
oriented so that the arrow at the inner end of W8 points toward the center of the wing.
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