Stevens Aero Model Build It! FullHouse 500 Manual

FullHouse 500
Electric Aileron Trainer Kit
Wing Span: 50 inches | Wing Area: 455 square inches | Average Flying Weight: 26 ounces
Build Instructions - Version 1.0 (revised 04.15.2014)
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 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
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 2

Kit Inventory
☐Laser cut wood (24 Sheets) See “Sheet Wood Inventory”
☐Build Instructions
☐Computer drawn detail sheets (2)
☐Pre-bent wire landing gear (1/8 in. diameter)
☐Ply Spar Doubler (W1c 1/32 Aircraft Grade Plywood)
☐Pre-Cut Acetate windshield
☐3 in. diameter Dave Brown lite wheels [DAV5530]
Taped to back of wood brick:
☐2 - 0.032 in. x 24 in. Wire
☐1 - 0.032 in. x 12 in. Wire
☐1 - 0.062 in. x 12 in. Wire
☐2 - 0.070 in. x 18 in. Nylon Pushrod Housing
☐Large Hardware Bag (5x8)
1 - Front Gear Block (Laser cut from SH655) *
1 - Rear Gear Block (Laser cut from SH655) *
1 - 3/16 in. x 3-3/4 in. Dowel 1025
2 - 3/16 in. x 2 in. Dowels 1022
2 - Du-Bro RC 936 Razor Control Horns (1 pkg.) [DUB936]
4 - Du-Bro RC 845 Mini E/Z Connectors (2 pkg.) [DUB845]
4 - Du-Bro RC 139 1/8 in. Dura-Collars (1 pkg.) [DUB139]
6 - #32 Rubber Bands, for Landing Gear
6 - XL Rubber Bands, for Wing Retention [HBZ127]
☐Small Hardware Bag (2x3)
1 - 1 in. length of 197 fuel tubing 4005
1 - 3/4 in. Tail Wheel (Sullivan) 4010
1 - Black Nylon Dished Washer 4016
4 - 4-40 Blind Nuts 3001
4 - 3/8 in. 4-40 Pan Head Screws 3007
4 - White Nylon Washers 3018
4 - Du-Bro RC 849 Micro E/Z Links 4017
4 - Neo. Magnets 1/16 x 3/16 in. diameter 4014
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 3

Suggested Items To Complete This Model
Many of the following items will be available at your local hobby shop. For your convenience Stevens
AeroModel stocks all of the power system components and most of the required and optional building
supplies. If you have difficulties sourcing any of the requisite items locally, please visit our web site to
purchase those items necessary to complete your model.
Required Electronics
☐4-6 Channel radio and micro receiver.
☐4 - HI-TEC HS-55 or HS-65HB servos (Rudder / Elevator / Ailerons)
☐2 - 6 in. Servo Extensions [SAA060EXT]
☐1 - 3 in. “Y” Connector [SAA030YXT]
☐SA Sport - Park BL450 950KV (A2217-9) Brushless Outrunner Motor [SUPA2217-9]
☐30 A Brushless ESC [SUP30AESC]
☐Hyperion 2s 2100 mAh 7.4V LiPo Battery [HP-LG325-2100-2S]
☐11 x 4.7 - 12 x 6 APC SF Propeller
Covering Film Requirements
While any high quality model film may be used to finish this model. Superior results will be achieved
using genuine AeroFILM brand model airplane covering film. The lower working temperature and
superior shrink of AeroFILM and AeroLITE are especially desirable for those new to covering model
airplanes. AeroLITE is 1/3 the weight of the typical model airplane covering film and will represent a
weight savings of 2 oz. when applied to this model.
☐2 - Rolls (2M) AeroLITE or AeroFILM
☐1 - Roll (1M) AeroTRIM
Required Building Supplies and Tools
☐1/2 oz. Thin CA Glue [PAAPT09]
☐1 oz. Medium CA Glue [PAAPT02]
☐1 oz. Thick CA Glue [PAAPT20]
☐Aliphatic Wood Glue (Carpenters Glue)
☐CA glue applicator tips [PAAPT21]
☐CA glue accelerator (kicker) [PAAPT15]
☐Balsa filler [HCAR3401]
☐Hobby Knife with ample supply of #11 blades
☐Sanding Block, Dual Grit [SB120240]
☐Heat Gun and Covering Iron
☐Medium Needle Nose Pliers
☐Electric Flyer Hinge Tape [DUB916]
☐Self-adhesive Velcro hook & loop [DUB348]
☐Soldering Iron
☐Masking Tape (Low tack “blue” painters tape)
Optional Building Supplies and Tools
☐CA glue de-bonder [PAAPT16]
☐CA glue bottle Z-Ends [PAAPT18]
☐Long sanding bar
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 4

Sheet Wood Inventory (Wing 1 of 2)
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 5

Sheet Wood Inventory (Wing 2 of 2)
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 6

Sheet Wood Inventory (Fuselage 1 of 3)
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 7

Sheet Wood Inventory (Fuselage 2 of 3)
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 8

Sheet Wood Inventory (Fuselage 3 of 3)
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 9

Builders Notes
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 10

General Assembly Instructions
Thank you, for purchasing this Stevens AeroModel FullHouse™ 500. This product 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 beginners who have purchased this kit to seek the help of a seasoned builder and pilot. 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.
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 sequence 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 we find it easier to tack glue part (temporarily bonding parts in
assembly using a small dot of glue) using medium CA glue applied with a fine-tip CA glue applicator tip.
Tight fitting joints should be bonded using thin CA glue applied, sparingly, with a CA glue applicator tip.
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, consider lightly sanding, or
lightly pinching, 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 airframe.
Manual Updates
Please check our web-site for updates to these instructions prior to commencing the build.
To obtain downloads and updates relative to this model aircraft kit, please visit the corresponding product
page at StevensAero.com
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 11

Fuselage
Fuselage parts are designated with an “F” followed by a numeric. Parts have been numbered so that the
fuselage assembly and required parts follows in numeric order from F1 to F58.
The fuselage is built upon a central crutch assembly. The top half of the fuselage will be built upon this
crutch first, then the assembly will be inverted and the bottom of the fuselage built. Many of the formers
will need to be installed in a forward and top 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. Assemble the Central Crutch from parts F1a and F1b. Bond with thin CA.
2. Assemble two side rails F2 from parts F2a and F2b. Bond with thin CA.
3. Fit side rails F2 to Left and Right of Central Crutch F1. Lay assembly on a flat surface and
bond all mating surfaces with CA.
4. Dry fit instrument panel F3 to the forward most slots in the crutch assembly. F3 will lean
forward slightly, and should not be glued until the fuselage sides are installed.
5. Fit 1/16 in. ply former F4 to the next set of slots back from F3. Note: The tabs on F4 will
only fill the outer portion of the slots. When the lower half of this former is installed, those
tabs will be off-set, and will fill the rest of the slot. Square to Central Crutch and tack glue.
6. Fit remaining formers F5 through F10, in numeric order, front to back, within the remaining
slots of the Central Crutch assembly.
7. Assemble two each Upper fuselage sides F11 and F12 by fitting and bonding F11a, F11b,
F11c to create F11 and F12a, F12b, F12c to create F12.
8. Dry fit fuselage side F11 to the tabs on formers F3, F4, and F5. Fit the dovetail tabs along
the bottom of the matching recesses in the crutch side rail F2. Lay assembly on a flat
surface and bond F11 to formers F3, F4, F5, and the central crutch side rail F2. Do not
bond the fuselage side F11 to formers F6 and F7 at this time.
Build Instructions
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Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 13
Step 1
Step 2
Step 3
Step 4
Step 8
Step 7
Step 6
Step 5
F1a
F1b
F2a
F2b
F1
F2
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11a
F11b
F11c
F11
F3
F4 F5
Do Not Glue
FRONT
Repeat for F12
F6 F7

Fuselage Continued
9. Follow the same procedure as in step 8 to install the opposite fuselage side F12. Again, do
not bond the fuselage side F12 to formers F6 and F7 at this time.
10. Fit spine part F13 to the top of formers F7, F8, F9, and F10.
11. Ensure F13 seats properly in the slots at the top of each former. Square assembly on a flat
surface and bond the spine to the formers.
12. Locate and identify diagonal braces F14a/b, F15a/b, and F16a/b.
13. Dry fit F14a to the slot in the spine ahead of former F8. The other end of F14a will rest in
the corner created by former F7, central crutch F1 and side rail F2.
14. In the same manner, dry fit F14b to the other side of the spine. F14b will fit in the slot in the
spine, keying into F14a, and resting in the corner created by former F7, the central crutch,
and the side rail.
15. Follow steps 13 and 14 to dry fit F15a and F15 b between formers F8 and F9.
16. Follow steps 13 and 14 to dry fit F16a and F16b between formers F9 and F10. Now,
square the fuselage assembly on a flat surface and bond the diagonal braces F14/15/16 to
the spine, formers and central crutch with thin CA.
Builders Tip! Review step 21 in manual and locate part F21 within position on fuselage.
Dry fit F21 (DO NOT GLUE!) to assembly prior to bonding diagonals as above. Fitting F21
at this time will ensure the proper positioning and square of all upper fuselage formers.
Only use F21 as a jig to assist in squaring your formers, after bonding the diagonal braces,
immediately remove F21 and set part aside until it’s once again called for in step 21 of this
manual.
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 14
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Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 15
Step 9
Step 10
Step 11
Step 12
Step 13
Step 14
Step 15
Step 16
F12
F13
F13
F7
F14/15/16a
F8 F7
F7
F8
F8
F9
F15a
F15b
F16a F16b
F9
F10
F4 F5 F6 F7
F7
F8
F9
F10
F14/15/16b
DO NOT BOND

Fuselage Continued
17. Locate parts F17, F18, and F19. Dry fit F17 and F18 to the base plate F19.
18. Dry fit the assembly to the slots in former F10. Place two scrap pieces of 3/32 in. wood
(from the same sheet that the fuselage sides came from or similar) between F19 and the
fuselage crutch to ensure the correct 3/16 in. spacing. Square the assembly over the
fuselage crutch and bond to former F10. Remove the scrap wood and bond F17, F18, and
F19 together with thin CA.
19. Fit the spine cap F20, with arrow facing forward, to the tabs along the top of the spine F13.
20. Moisten the outside surface of the fuselage sides, with glass cleaner, near the rear where
they will bend over formers F6 and F7. Allow the glass cleaner to soak in for a few minutes,
then pull the fuselage sides together against the formers and retain in place using masking
tape. Now, allow the soaked/bent sides to dry. When the sides have dried thoroughly, tack
glue them to the fuselage formers with medium CA glue.
21. Fit the wing saddle F21 to the tabs on top of formers F4, F5, F6 and the spine F13. Square
the fuselage assembly on a flat surface and bond F21 to the formers, fuselage sides, and
spine.
22. Fit and bond forward dowel mount F22 to the tabs at the front of F21, and the slots in the
fuselage sides.
23. Dry fit doubler F23 against the inside of one fuselage side, forward of the instrument panel
F3, to check the orientation of the part. Remove the doubler and coat the mating surface
with thick CA or a slow setting aliphatic wood glue (carpenters glue). Replace the doubler,
pressing firmly into place, and remove any excess CA that oozes out around the edges.
Wick a little thin CA around the edges to bond the doubler to the fuselage crutch and former
F3. Repeat this process to install doubler F24 against the inside of the opposite fuselage
side.
Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 16
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Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 17
Step 17
Step 17
Step 18
Step 19
Step 22
Step 23
Step 21
Step 20
F17
F19
F18
Scrap
F20
F7
F21
F22
F23
F24
This Gap OK!

Fuselage Continued
24. Repeat the procedure in Step 23 to fit and install doublers F25 and F26 within the fuselage
sides inside of doublers F23 and F24.
25. Sand fuselage sides where they may extend aft of former F7. Fuselage sides must finish
flush with the back side of former F7 before proceeding (represented by a dashed line in the
assembly photo). Now, on parts sheet 09/24 you will find several strips of wood marked
“Fuselage Stringers”. Remove the two 3/16 in. square stringers that measure 18 in. long.
Dry fit, one each, stringer within the right and left side notches of formers F7, F8, F9 and
F10. Note: The forward end of the stringer should seat flush within the notch of the
fuselage side at F7.
26. The 3/16 in. square stringers installed above will terminate along F17/F18. Square the
assembly on a flat surface and bond the stringer to each former, the fuselage sides, and
F17/F18.
27. Locate part F27 and fit between the fuselage stringer and the left side rail F2. When
installed correctly, the etched part number will be right-side-up and on the outer face of the
part. Bond with thin CA.
28. Repeat the process in step 27 to install part F28 on the right side of the fuselage.
29. Locate two sets of parts F29a, F29b, and F29c. These will form the right and left Rear Wing
Dowel Mounting Block. Make two stacks in order: “a” on the bottom, then “b”, then “c”.
Note that the grain of parts F29b run vertical, while the grain of parts F29a and F29c run
horizontal. When assembled, this will create a strong, cross-grained block. DO NOT
BOND.
30. Use the longer of the 3/16 in. diameter dowels, supplied with your kit, as a jig to assist with
the installation of the Rear Wing Dowel Mounting Block. Slide the dowel through the hole in
the spine F13 immediately behind former F7. DO NOT BOND! This dowel must be
removed after this assembly step. With the concave edge of parts F29a/b/c facing aft,
slide a complete set of parts F29a/b/c onto each end of the dowel, at right and left side of
the spine. Using SMALL drops of medium CA, tack glue parts F29 to each other, the spine
F13, former F7, and the fuselage stringer underneath. Now, remove the dowel from the
assembly and wick thin CA between the parts F29 and the spine, former, and stringer.
Ensure that the hole through the mounting block is not blocked by excess use of glue.
Builders Tip! If you find that you’ve inadvertently tack glued the dowel within the assembly,
quickly grab a pair of pliers, grip an end of the dowel, and give a firm twist to break the CA
glue bond. If you’ve thoroughly bonded this dowel within the assembly you’ll need to leave
it be, cut and sand it flush, and later drill the hole back out.
The risk of bonding this dowel within the fuselage almost outweighs the benefits of using
CA glue in this step. If you are careful with your CA glue application and understand the
usage of medium and thin CA glues you should have no problem completing the step above
as described. Otherwise we suggest using a slow set aliphatic wood glue (carpenters glue)
or white glue to bond these parts together giving adequate time to align parts and remove
the dowel.
Build Instructions
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Build Instructions
FullHouse™ 500 Build Instructions. © 2012 Stevens AeroModel. All rights reserved.!Page 19
Step 24
Step 24 Cont.
Step 25
Step 26
Step 27
Step 28
Step 29
Step 30
F23
F25
F24
F25
F26
F27
F28
F29a
F29b
F29c
3/16 in. dowel
3/16 sq. stringer
3/16 sq. stringer
Do not bond this dowel
within assembly!
LEFT
RIGHT
F17 F18

Fuselage Continued
31. Using a sharp hobby knife or single edge razor blade to carve off most of the excess
material from the Rear Wing Dowel Mounting block. Use a sanding block loaded with 120
and 240 grit sandpaper to finish shaping F29, fairing it smoothly into the fuselage side,
spine, stringers and F27/F28.
Builders Tip! You have an idea of what needs sanding, you also know what you don’t want
to sand. Rather than just set off with the sanding block risking inadvertently over-sanding
and or gouging parts that don’t require shaping or reducing, spend some time protecting the
delicate sheeting and stringer areas with masking tape. Thats right! A single layer of
masking tape placed over delicate balsa areas will protect these from the sanding action.
Only remove this tape when you are ready to finish sand both the shaped area and the
fuselage to flow these areas together.
32. Trim if necessary, then sand the rear of the fuselage stringers to taper to the tail of the
model.
Congratulations, The upper half of the fuselage assembly is now complete go feed the dog
a biscuit (he deserves it), then when you get back, turn the fuselage up-side-down and
continue with the construction of the bottom half.
33. Fit and tack glue the 1/16 in. ply former F30 to the slots immediately beneath ply former F4.
34. Fit and tack glue the 1/8 in. lite ply former F31 to the slots immediately below former F5.
35. Fit and tack glue the 1/8 in. lite ply former F32 to the slots immediately below former F6.
36. Fit the 1/16 in. ply Battery and Servo Tray F33 to formers F30, F31, and F32. (Note F33
may not appear EXACTLY as illustrated in this photo as minor modifications have been
performed by our excessive-compulsive engineer on this part to enhance the model’s long-
term durability.)
37. F33 will nest within the recesses in the base of each former. The slots along the edge of
F33 will engage the formers themselves. Check for proper and complete fit of parts then
bond F33 to the formers.
38. Fit former F34 first to the slots in the central crutch immediately below former F7, then to
the tabs in the end of F33. Tack glue F34 to the central crutch and F33.
Build Instructions
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