Stevens Aero Model Avro 558 Manual

1923 Avro 558
A record setting motor glider from the 1923 Lympne light aircraft trials.
Wing Span: 33 inches | Wing Area: 205 square inches | Average Flying Weight: 7 ounces
Build Instructions - Version 1.24 (revised 08.21.2014)
Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 1

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
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 2

Avro 558 - Kit Inventory
☐Laser-cut wood, 12 sheets (See Sheet Wood Inventory, page 5 and 6)
☐Illustrated Build Instructions
☐Detail Sheet, 1 sheet, 11 in. x 17 in.
☐4 - Balsa stripwood, 3/16 in. x 3/16 in. x 24 in.
Taped to back of wood brick:
☐1 - Wire, .063 in. x 12 in. (Landing gear)
☐2 - Wire, .032 in. x 18 in. (Push rods)
☐2 - Nylon tube, yellow, .070 OD x 12 in. (Push rod housing)
Hardware Bag:
☐1 - Wheels, pair, spindle style (DUB200ML)
☐1 - Aluminum tube, 1/16 in. x 2 in.
☐1 - Hardwood dowel, 1/8 in. x 2 in.
☐1 - Part F5, 1/8 in. lite plywood (laser cut)
☐1 - Blind nut, 4-40
☐1 - Nylon screw, 4-40 x 3/8 in.
☐1 - Nylon hinge, small Du-Bro RC [DUB118]
☐1 - Tail skid, delrin (laser cut)
☐2 - Wing tip skid, delrin (laser cut)
☐2 - E/Z connectors pkg. [DUB845]
☐2 - Micro E/Z links [DUB849]
☐2 - Nylon washers, black dished [4016]
☐6 - Screws, #0 x 3/16 in. [3010]
☐8 - Neo-magnets, 3/16 in. dia. x 1/16 in. thick [4014]
Avro 558 - Background
The Avro 558 biplane motor glider, was designed for the 1923 Lympne light aircraft trials. It is certain to
delight, with it long slender lines and efficient glide. Two examples were built. The aircraft did not win the
competition, but one later went on to establish a altitude world record for its class of 13,850 ft.
Our sport-scale model of the Avro 558 was designed and manufactured in the USA using industry leading
construction methods and innovative laser cutting techniques, Stevens AeroModel hand selects only the
highest quality AAA balsa and hard woods from select state-side mills. To ensure builder success the
thoughtful design and materials selection is backed by a thorough step-by-step photo illustrated
instruction manual, clear drawings, and a comprehensive hardware package. StevensAero.com cordially
invites you to experience the satisfaction of building and flying this one-of-a-kind sport-scale model
airplane.
Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 3

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 the model.
Required Electronics
☐RC transmitter and micro receiver with at least 3 channels
☐Servos, two required, Hitec HS-35HD
☐Motor, SA Sport BL-250 brushless (SUPA1510/15)
☐Speed control, 10A brushless (SUPA10AESC)
☐Propeller, 6x3 GWS HD (GW/EP6030)
☐Propeller adapter, 2mm (EFLM1927)
☐Battery, 550 mAh 7.4V LiPo (LG325-550-2S)
Covering Film Requirements
While any high-quality covering film may be used to finish this model, superior results will be achieved by
using genuine AeroLITETM brand covering film, available exclusively from Stevens AeroModel. The lower
working temperature and light weight of AeroLITETM are especially desirable for this type of model.
AeroLITETM is one-third the weight of typical model covering films, and will present a significant weight
savings when applied to this model.
☐1 - AeroLITETM roll (2M)
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)
Build Instructions
Avro 558 - Build Instructions © 2014 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 400 and 600 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 (DUB348)
☐Masking tape (low-tack blue painters’ tape)
☐Drill bit, 1/16 in. dia.
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®)

Sheet Wood Inventory (1 of 2)
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Sheet Wood Inventory (2 of 2)
Build Instructions
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General Assembly Instructions
Thank you for purchasing the 1923 Avro 558 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 250 - 400 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 thin 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
Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 7

Fuselage
Fuselage parts are designated with a “F” followed by a numeric. Parts have been numbered so that the
fuselage assembly and required parts follows in numeric order from F1 to F38.
The fuselage is of traditional sheet side with central crutch assembly. Many of the formers will need to be
installed in a forward and top/bottom orientation. Unless otherwise specified, formers should be installed
with the etched part number facing the front of the assembly and any top or bottom designations followed.
You will dry fit the majority of this fuselage assembly together only gluing at the final instructional steps.
When parts cannot easily be retained with friction, use a single tiny drop of medium CA glue applied
sparingly through 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 fit in error if you do
not slather the assembly in glue after each step! Further, this method of assembly will allow our
interlocking design to do it’s job as each successive part installed within the fuselage will help pull the
entire structure square and true.
1. Lay part F1 (sheet 12/12, 1/16 in. ply) on the work surface with the etched side marked
“Bottom” facing up. Press a 3/16 in. dia. x 1/16 in. neo-magnet into the hole at the front of
F1, and bond by wicking CA around the edges of the magnet.
2. Next, press another neo-magnet into the hole at the rear of F1, and bond with CA.
3. Assemble F2, beginning with parts F2a and F2b (sheet 09/12, 1/16 in. balsa), and bond
where the parts fit together at the rear.
4. Fit and bond cross pieces F2c through F2h (sheet 09/12, 1/16 in. balsa) in order from the
front (wide) end of F2, proceeding toward the rear of F2.
5. Fit the completed F2 assembly to the rear of F1 and bond with CA.
6. Ensure that F1/F2 are laying on the work surface with the etched “Bottom” side facing up.
Fit former F3 (sheet 09/12, 1/16 in. balsa) to the crosspiece F2h, with the arrows on F3
pointing toward the cross piece, and “tack glue” with medium CA.
7. Fit and “tack glue” former F4 (sheet 09/12, 1/16 in. balsa) to the cross piece F2f, with the
arrows pointing toward the cross piece.
8. Wing Mount: Locate ply part F5 and lay it on the work surface with the etched side facing
up. Press the 4-40 blind nut found in your hardware bag into the hole in the middle of F5
until it is firmly seated. A small hammer may be used to assist in seating the nut. Bond by
wicking small drops of medium CA around the flange on the nuts.
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Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 9
Step 1
Step 2
Step 3
Step 4
Step 8
Step 7
Step 6
Step 5
F1
Bottom
Neo-Magnet
F1
Bottom
Neo-Magnet
F2a
F2b
Bond
F2c
F2d
F2e
F2f
F2g
F2h
F1
F2
Bond
F3
F4
F5
4-40 Blind Nut

Fuselage (continued)
9. With F5 laying on the work surface, with the flanged side of the nut facing up, fit ply parts F6
and F7 (sheet 12/12, 1/16 in. ply) to the slots at each end of F5. Orient F6 and F7 so that
the tabs point in the same direction as the tabs on F5. Bond with medium CA.
10. Lay former F8 (sheet 10/12, 1/16 in. balsa) on the work surface and fit the completed Wing
Mount assembly to the slots at the bottom of the former. Bond with medium CA.
11. Fit and tack glue former F8 to the cross piece F2d, oriented with the wing mount pointing
toward the front of the assembly.
12. Fit the servo plate F9 (sheet 12/12, 1/16 in. ply) to F8, ensuring that the arrows on F9 point
forward.
13. Fit and tack glue F10 (sheet 12/12, 1/16 in. ply) to F1 and the front of F9.
14. Fit part F11 (sheet 08/12, 1/16 in. balsa) to the slot in F10, covering the Neo-magnet at the
rear of F1. Bond F11 to F1 and F10 with CA.
15. Fit the ply strut mount plate F12 (sheet 12/12, 1/16 in. ply) to the slots in F1 immediately
forward of former F10.
16. Fit former F13 (sheet 12/12, 1/16 in. ply) to the next set of slots in F1, immediately forward
of F12.
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Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 11
Step 9
Step 10
Step 11
Step 12
Step 16
Step 15
Step 14
Step 13
F7
F6
Flange
F8
F8
Forward
F9
F10
F11
F12
F13
Tabs

Fuselage (continued)
17. Fit parts F14 and F15 (sheet 09/12, 1/16 in. balsa) in the notches along the bottom of
formers F10 and F13. Orient F14 and F15 with the arrows pointing forward, toward former
F13. “Tack glue” with medium CA.
18. Landing Gear Mount: Fit ply landing gear mount F16-L (sheet 12/12, 1/16 in. ply) to the
slot marked “L” at the front of F1, with the tabbed edge pointing forward. “Tack glue” with
medium CA. Fit and tack glue F17-R (sheet 12/12, 1/16 in. ply) to the slot marked “R”, with
the tabbed edge pointing forward.
19. Fit part F18 (sheet 08/12, 1/16 in. balsa) over the neo-magnet between the landing gear
mounts, with the etched side marked “Bottom” facing up. ensure that the notch at the front
edge of F18 aligns with the notch at the front of F1, then bond with CA.
20. Fit part F19 (sheet 12/12, 1/16 in. ply) to F16 and F17, ensuring that it is fully seated
against the landing gear mounts. “Tack glue” with medium CA underneath W19, where it
mates with F16 and F17. Do not allow any glue around the tabs on F16/F17 that protrude
beyond F19, as this will interfere with the fit of part F20 in the next steps.
21. Fit ply part F20a (sheet 12/12, 1/16 in. ply) to the tabs at the front of the landing gear mount
assembly, ensuring that the outer edges align with the edges of F19. Bond by wicking CA
around the outer edges of F19/F20a. Do not allow any glue around the inner edges of
F20a, as this will interfere with the installation of the landing gear wire in a later step.
22. Fit F20b (sheet 12/12, 1/16 in. ply) to the tabs at the rear of the landing gear mount
assembly. Bond by wicking CA along the rear edge of F19/F20b. Ensure that no glue
enters the slot between F20a and F20B.
23. Landing Gear: Bend the landing gear over the pattern on the detail sheet, using the 12 in.
length of .062 wire supplied in your kit. Proceed carefully, accuracy is critical for a proper fit.
24. Cut the plastic retainers from the inside of the wheels (DUB200ML) supplied in the kit.
Discard these retainers, they will not be used in this model.
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Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 13
Step 17
Step 18
Step 19
Step 20
Step 24
Step 23
Step 22
Step 21
F14
F13
F10
F15
F1
F16-L
F17-R
L
R
F18
Bottom
F19
F20a
F20a
F20b
Tabs
Bond
No Glue

Fuselage (continued)
25. Enlarge the axle hole in the wheels using a 1/16 in. drill bit.
26. Bond the wheel covers WH (sheet 10/12, 1/16 in. balsa) to each side of the wheel by
wicking CA around the outer edges.
27. Sand the wheel covers to a streamlined shape - thick in the middle, tapering toward the
outer edges until flush with the outer edges of the wheel. Cover the completed wheel
covers to match the color scheme of your model.
28. Press the two dished washers onto the landing gear wire, one at a time, and remove. This
step slightly enlarges the hole in the washers, allowing for and easier installation in a later
step.
29. Feed the landing gear wire through the fuselage crutch assembly, between formers F10 and
F13, and under parts F14 and F15.
30. Raise the legs of the landing gear wire, trapping parts F14 and F15.
31. Slide wheels onto landing gear wire and ensure that they spin freely. If the wheels do not
spin freely, ream the axle hole with a 1/16 in. drill bit until they spin freely on the axle.
32. With the wheels mounted, mark the landing gear wire 1/8 in. beyond the outer face of the
each wheel. Remove the wheels and trim the wire at this mark.
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Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 15
Step 25
Step 26
Step 27
Step 28
Step 32
Step 31
Step 30
Step 29
WH
WH
Sand to a
Streamlined
Shape
Cut
1/8 in.

Fuselage (continued)
33. Remount the wheels and retain by pressing a dished washer - rounded side out - onto the
axle.
34. Apply thick CA to the groove in F20, and press the landing gear wire into the groove until it
is fully seated. Spread thick CA over the entire surface of F20, then fit ply part F21 over it,
pressing it firmly in place. Wipe up any excess glue before it cures.
35. Lay former F22 (sheet 12/12, 1/16 in. ply) on the work surface with the etched “Back” side
facing down. Press two neo-magnets into the two holes on the right side of the former.
Wick CA around the edges of the magnets to bond in place.
36. Turn F22 over, so that the side marked “Back” faces up. Position F23 (sheet 8/12, 1/16 in.
balsa) over the neo-magnets within the etched outline. Wick CA around the edges of F23
to secure.
37. Fit F22 to the front of F1 and the landing gear mount assembly. Ensure that the side
marked “Back” faces the rear of the fuselage, and that the exposed magnets are on the
right side of the assembly. “Final bond” F1, F22, and the landing gear mount assembly
together with medium CA. Built up a small fillet of glue along each seam to further
strengthen these joints, as they are under considerable stress during landings.
38. Fit the scale motor mount F24-L (sheet 12/12, 1/16 in. ply) to the slots on the left side of
F22.
39. Fit F25-R (sheet 12/12, 1/16 in. ply) to the slots on the right side of F22.
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Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 17
Step 33
Step 34
Step 34 Cont.
Step 35
Step 39
Step 38
Step 37
Step 36
Washer
F22
Back
F21
Neo-Magnets
F22
F23
Front
Back
Magnets on
Right Side
F24-L
F24-L
F25-R

Fuselage (continued)
40. View the assembly from the bottom of the fuselage, and ensure that F24 and F25 are
parallel with each other, and with the inner edges of F1. When you are satisfied that F24
and F25 are aligned correctly, bond them to F22 with CA.
41. Assemble the right fuselage side F26 from parts F26a and F26b (sheet 10/12, 1/16 in.
balsa). Bond with CA.
42. Fit F26 to the right side of the fuselage assembly, beginning at F22 and proceeding toward
the rear of the assembly. Lightly “tack glue” where necessary.
43. Repeat steps 41 and 42 to assemble and install the left fuselage side F27 (sheet 09/12,
1/16 in. balsa). Lay the assembly up-side down on a flat surface, allowing F22 to hang over
the edge. Square the assembly, then final bond all mating surfaces between the formers
and the top, bottom, and sides of the fuselage.
44. Fit doublers F28 and F29 (sheet 08/12, 1/16 in. balsa) to inside the wheel well, flush against
the fuselage side. Ensure that the arrow on F28/F29 points forward. The tabs at each end
of the doublers will engage the notches in formers F10 and F13.
Ensure that the doublers are fully seated, leaving a recess against the fuselage side at the
rear of each doubler. Bond the doublers by wicking CA along the edges of the fuselage
side, and where the doublers contact formers F10 and F13. Do not allow and glue to enter
the recesses at the rear of the doublers.
45. Assemble the fuselage bottom from parts F30a through F30e (sheet 10/12, 1/16 in. balsa)
and bond with CA.
46. Fit and bond doubler F30f (sheet 10/12, 1/16 in. balsa) to the notches at the bottom rear of
the fuselage sides. Ensure that F30f is fully seated, leaving a recess to receive the tabs at
the rear of F30.
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Build Instructions
Avro 558 - Build Instructions © 2014 Stevens AeroModel, all rights reserved.!Page 19
Step 40
Step 41
Step 42
Step 43
Step 46
Step 45
Step 44 Cont.
Step 44
Parallel
F26a
F26b
F26
F27
F28
Recess
F28
F10
Fuselage
Bottom F30
a
b
c
d
e
F30f
Recess
Forward
Bottom View
F10
F13

Fuselage (continued)
47. Fit F30 to the notches along the bottom of the fuselage sides, and the tabs on each former.
Square the fuselage on a flat surface, and final bond F30 to the fuselage sides and formers.
48. Fit part F31 (sheet 11/12, 1/8 in. balsa) to the recess at the rear of the fuselage, ensuring
that the slotted side faces aft. Bond F31 to the fuselage by wicking CA around the edges
where it contacts the fuselage side. Ensure that no glue enters the slot in F31, as this will
receive the rudder hinge in a later step.
49. Fit parts F32a and F32b (sheet 08/12, 1/16 in. balsa) together to make the forward fuselage
bottom. Note that one side of F32a is etched “Bottom”.
50. Fit the F32 assembly to the forward bottom of the fuselage, ensure that the side etched
“Bottom” faces out. Bond F32 to the fuselage sides, formers and scale engine mounts with
CA.
51. Locate part F33 (sheet 08/12, 1/16 in. balsa). Note that the concave edge is the front of the
part, and the straight edge with the notch in the middle is the rear. The notch will engage
the tab at the top of former F22. Moisten one side of F33 with glass cleaner and allow to
soak for a minute or two. This will aid F33 in forming around the top of F22.
52. Fit F33 to the top of F22, moist side out, and hold in place with low tack masking tape until
dry. While F33 is drying ensure that the front of F33 matches the radius of the top of F22.
This is critical to ensure proper clearance for the motor to spin freely when installed. Gentle
shaping with your finger tips while the part dries will ensure it assumes the proper shape.
When F33 is completely dry, remove the tape and final bond F33 to F22 and the front of F1.
53. Fit and bond former F34 (sheet 09/12, 1/16 in. balsa) to the slots at the rear of F1, ensuring
that it is perpendicular to F1.
54. Fit and bond former F35 (sheet 09/12, 1/16 in. balsa) to the slots in crosspiece F2e.
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