Stevens Aero Model CAP 232 User manual

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A 1:8 Scale SPEED 300 POWERED AEROBAT
CAP 232
S300/S300 SPT (R2.05)
Span 36.45” / Length 33.3” / Area 245 Sq.” / Weight 14.5-16.5oz
Copyright 2005 Stevens AeroModel

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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.
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 the use by
the user of the final user-assembled product. 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.
Copyright 2005 Stevens AeroModel

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REQUIRED TO COMPLETE KIT:
Kit Contents:
1. Computer Drawn Plan Sheet
2. Illustrated Instruction Manual
3. Laser Cut Balsa Parts Sheets (See Parts Inventory Sheet)
4. 1 - Clear Canopy
5. 1 - Cowl Assembly
6. 4 - 1/4” Square x 18” Balsa Sticks (Leading Edge) [4 - 3/16” Square S300-SPT]
7. Large Hardware Bag
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1 - 1/32” Laser Cut Plywood Parts Sheet.
1 - 1/16” Laser Cut Plywood Parts Sheet.
2 - 1/8” x 4.5” hardwood dowel.
2 - 1/8” x 1.25” hardwood dowel.
1 – 1/8” LitePly EPS Motor Mount. Assembly.
1 - Bag #16 Rubber Bands (10).
2 - 1/32” x 12” Music Wire.
2 - Pre-Bent Wire Landing Gear.
1 - 3/32” x 6” aluminum tube.
2 - 12” Length of plastic tubing.
1. Small Hardware Bag
8 - #0x3/16” Screws (Wheel Pant Hardware).
1- Length of Kevlar Thread.
1 - 1/16” x .25” aluminum tube.
4 – 1”x3/4” CA Hinge Material
2 – 4x40 Blind Nuts. (Optional bolt on wing)
2 – 4x40 Nylon Wing Bolts. (Optional Bolt On Wing)
Recommended Finishing Items:
1. GWS LFW-381 1.5” Lite Wheels (2-Pack).
2. Sullivan 1/2” Tail wheel.
3. Dubro Micro Pull/Pull Assembly DUB846
4. Dubro Mini E/Z Connectors DUB845
5. 1 Roll of Covering + Trim (AeroFILM Lite AKA - Nelson Lite Film, or Solarfilm So-Lite recommended)
6. 1.5” Spinner
Suggested Electronics:
1. 4 Channel Transmitter (Using Y-Servo Extension for Ailerons)
2. 4 - Sub Micro Servos (Hitec HS-55, GWS Naro HPBB, or JR 241)
3. 1 - 6” Y-Servo Extension
4. 2 - 6” Servo Extension
5. 1 - Micro Receiver
6. 1 - Micro ESC (10 Amp)
7. 1 - GWS EPS350C-CS Motor - Gear Box
8. 1 - GWS Slow-Fly Prop 9x7.
9. 1 - 8 Cell 650KAN NIMH.
Brushless Power Systems:
1. Castle CM2068 GWS GB 6.6:1 / 10x6 GWS HD Prop / 11.1v 1320mAh Thunder Power PL LiPoly.
2. Hacker A20-20L / Direct Drive / 9x5 E Prop / 11.1v 1320mAh Thunder Power PL LiPoly – requires motor
adapter.
Items You May Need:
1. Thin and Thick CA (super glue)
2. Five Minute Epoxy
3. Wax Paper or Plastic Wrap
4. Razor Blade(s)
5. Rat-Tail File
6. Clear Tape
7. Balsa Wood Filler
Copyright 2005 Stevens AeroModel

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GENERAL ASSEMBLY INSTRUCTIONS:
Thank you, for purchasing this Stevens Aeromodel 1:8 Scale CAP 232 – Park Flyer. This kit provides the builder and pilot
a refreshing change of pace from heavy “ARF” style plywood box airframe construction and blends stick and tissue design
methods of the past with state of the art CAD technology and precision interlocking laser cut parts; the result is something
you will find truly exceptional to build and truly exceptional to fly. Please keep in mind that this kit is intended for a
novice-intermediate builder and experienced pilot. If you do not meet these criteria it is recommended to seek help from a
more experienced builder / pilot.
Sincerely,
Bill Stevens
[email protected]
Stevens AeroModel “Built to Fly”
4550 Beaumont Rd.
Colorado Springs, CO 80916
Assembly Tips
1. READ THE INSTRUCTIONS and the plan sheet prior to starting any work!
2. Tape plans to work table. Cover with wax paper or plastic wrap.
3. Join all joints with Thin CA unless otherwise specified.
4. DO NOT REMOVE THE PARTS FROM THE BALSA SHEETS UNTIL REQUIRED!
5. DO NOT FORCE THE FIT – when in doubt double check your parts - removal of material should not be
required. If you feel that you have a poor connection check first to see that the part is not upside down. Next,
reference each piece against the plan sheet.
6. This is very important so I’ll say it again - Prior to gluing, test fit and match parts over the plan sheet to ensure
you have the correct pieces and orientation.
7. Making solid glue joints: Hold parts together on top of plan sheet using moderate pressure to fit parts - wick thin
CA into joint. (There is no need to pin parts to work table as all pieces interlock and self - jig.)
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Tail Feathers
1. Build the Rudder, Vertical Stabilizer, Elevator, and Horizontal Stabilizer. Parts are grouped according to tail
section component on the 1/8” balsa sheet. Work with each component separately. Assemble over plan sheet,
removing only those parts necessary to complete each individual component. Start each assembly by building
up the outside edges (just like a puzzle) – finish by inserting center truss parts. Though the parts fall together
and self jig, pay particular attention orientation and making solid glue joints.
F
Horizontal
Stab.
E
E
D
D
AA
Elevator
C
BB
EE
F
C
3
32"
Aluminium
Tube
FF
CC
BB
Vertical
Stab.
D
DF
F
I
I
H
H
E
E
G
G
Rudder
2. Elevator Joining Tube. Verify that the provided 3/32” aluminum tube is of the appropriate length and rough the
surface with fine grit sand paper to remove dirt, oil, and debris, from the tube. Wipe tube with rubbing alcohol,
then Using thin CA tack the joining tube to each elevator halve and allow to dry. Once dry use a small amount
of 5-minute epoxy to create a fillet between the wood and the metal tube.
3. Sand all surfaces with fine grit sand paper and bevel / taper hinged surfaces in preparation for your preferred
hinging method (CA Hinges Recommended).
Fuselage
Fuselage components are exceptionally brittle until the entire assembly is complete. Handle parts accordingly and do not
force the fit!
1. Join F16A and F16B over plan sheet to create part F16 (fuselage side sheeting).
2. Assemble formers F4, F5, and F6. Join over plan sheet F4A, F4B, F4C, F4D, F5A, F5B, F5C, F5D, F6A, F6B,
F6C.
Copyright 2005 Stevens AeroModel

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3. Assemble fuselage sides over plan sheet. Parts are grouped on the 1/8” balsa sheet. Make 2 sides.
4. Assemble part F1B (Glue cross braces to part). Join fuselage sides to F1, F2 and F1B. Test fit parts before
gluing. F1 and F2 are preset for 2 degrees of right thrust when using the GWS type motor systems and are
clearly marked “FRONT” make sure they are installed in the appropriate direction to avoid thrust angle issues.
SA
F1 (FRONT) F2 (FRONT)
GWS
F1B
(note: The photo shows old style F1/F2 formers the line drawing depicts the updated 2.03 former assemblies)
5. Laminate SR1 to SR2 to produce two servo rail parts. To complete the servo rail assembly, nest the tabs in
SR3 (balsa) radio tray to the notches in the servo rail parts. Refer to plan sheet for more detail.
6. Install formers F3, F3A, F3B, F3C, and completed servo rail assembly (Site fuselage construction over plan
sheet top view to ensure straight and true assembly.)
F3
F3A
F3C
F3B
Copyright 2005 Stevens AeroModel

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7. Test fit and secure fuselage brace pieces F16. Parts F16 keys to the top of F3C and the fuselage sides (See
Illustration).
F16
F16
BB
F3C
F16
F15
HS-55 C
F4
C
8. Glue F14 1/8” stringers to top of F1, F2, F3, F3A.
9. Install 1/16” Plywood BT1 Battery tray
BT1
Copyright 2005 Stevens AeroModel

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10. Pinch fuselage sides together at tail position, using a flat rat-tail file bevel the notches and alignment tabs in the
fuselage to better accommodate formers F4, F5, and F6.
11. Assemble part F15 (Glue cross braces to part). Test fit former F4 and F15 to fuselage. Align over top view on
plan sheet and secure with thin CA. Hint: Sand a slight bevel on sides of former F4 to aid fit. Again, do not
force fit!
12. Proceed to install former F5 and F6 inserting F13 along the bottom of the formers to jig the assembly. Initially
test fit F5 and F6 then glue F5 and F6 to fuselage sides. Only glue F13 where it makes contact with F4, F5,
and F6 – Do not glue F13 to fuselage sides at this time!
13. Test fit former F7. Capture aft section of F13 between fuselage sides, again do not glue at this time.
Copyright 2005 Stevens AeroModel

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14. Place some sort of weight over servo rails. Using a builders square hold tail section 90 degrees to building
table and glue F7 and F13
15. Add tail gear block F11 to aft section of F13 inside fuselage. Laminate 1/16” ply tail wheel bracket to underside
of fuselage (align edges with aft end of fuselage – refer to plan sheet for more detail.
16. Laminate F10 in position over aft section of fuselage. Important - Key F10 to top of F7 and tab into F6.
Copyright 2005 Stevens AeroModel

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17. Laminate F9 to F10, key to F7. DO NOT align with holes provided in F10 but key to F7.
18. Test fit F12 to F8. Lay F8 on building table, press F12 into F8 and glue.
19. Test F12/F8 assembly to formers F4, F5, and F6 (do not glue until specified). Align aft edge of F8 with aft edge
of F9 tack glue just the aft end of both parts.
20. Test fit horizontal stabilizer in the slot created between F10 and F8. Snug F6 against F12/F8 assembly –
remove horizontal stab and glue. Finish gluing parts F8 and F9.
21. Glue F12/F8 assembly to F4 and F5.
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22. Laminate finishing blocks to top of F8.
23. Sheet fuselage sides with F16.
F16A
F16
F16B
24. Sheet fuselage top/front with F17A and F17B. Test fit – then secure one end with thin CA. Next, gradually tack
down the sheets to the formers with thick CA.
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25. Key F3D to fuselage and glue to F4.
26. Prior to sheeting turtle deck, route elevator and rudder pull / pull tubing. Locate the .032” ID micro tubing
provided in the hardware bag. Run one tube for the elevator (it doesn’t matter what side you run it out of)
through F3D and secure through hole in one side of F5 where your elevator pull / pull cable will exit through
turtle deck. The rudder pull / pull tube should route through F3D and the slot in F13 – extending approximately
3/8” below fuselage. Secure Pull/Pull tubing with a small dab of 5-Minute epoxy at each plastic to balsa joint.
27. Sheet the Turtle Deck with F18 (It helps to pre-sand the turtle deck slightly) If necessary, soak the turtle deck
with rubbing alcohol to soften wood and facilitate bending around the radius of the turtle deck. Test fit – then
secure the bottom of the turtle deck sheeting to the fuselage longeron working from the aft end forward tacking
in place with thin CA. Next, gradually tack down the sheets to the formers with thick CA. The turtle deck will
run long and extend beyond former F3D. Finally, trim and sand leading edge of turtle deck sheeting flush with
the front of F3D.
Copyright 2005 Stevens AeroModel

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28. Carve and sand aft section of turtle deck round.
Motor Mount:
1. Locate the 1/8” Lite ply motor mount assembly (Large Parts Bag). Assemble parts with thin CA to form motor
mount stick. Lightly sand motor mount stick lightly until your GWS gearbox slips on to mount (excessive force
should not be required)– once satisfied fit mount stick to fuselage ARROW FORWARD. Use the upper most
mount etched “GWS” to mount the GWS EPS-300C/EPS-400C motor systems (The lower 10mmx10mm mount
holes should be used when mounting the optional Stevens AeroModel Hacker B20L and Mega 16/15/x modular
plywood motor adapters). The fit will be snug through formers F1 and F2 – go easy here sand slightly if
required. Slide GWS gearbox onto mount supporting the backside of the motor stick. IT IS REQUIRED to drill
a small hole through gearbox and stick and pin with a small screw (not provided) to ensure the motor
does not come off in-flight.
F1 (FRONT)
GWS
GWS EPS 300C / EPS 400C
Stevens AeroModel Modular
Motor Mount.
SA
For optional brushless motors that do not make use of the GWS gearbox:
1. Purchase the appropriate OPTIONAL motor adapter and assemble as per instructions.
2. Prepare 10mm square motor mount stick as above and insert into lower hole etched “SA”.
Copyright 2005 Stevens AeroModel

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Stevens AeroModel Motor Adapter
- Hacker B20L 4:1
- Mega 16/15/x Direct
(Supports a wide variety of popular brushless motors.)
0 / 0
F2
F1B
F1
AA
1/16" Ply Battery Tray
F3
Wing
Assemble wing upside down - all rib pieces have built in jig and allow for a straight and true wing final assembly when built
in this fashion. Do not break jig off of rib pieces until you have completed wing assembly.
1. Join S1 to S2 to create main spar.
S1S1
S2
2. Key wing ribs R1, R2, R3, R4, R5 and R6 onto main spar. Nest 1/8” square S4 main spar doubler along top of
main spar capturing ribs R1-R6. Align over plan sheet upside down and glue entire assembly.
R2
R3
R5
R1 R4
R6
3. Locate ribs R1 (3/32”) and R2 (1/16”) and CA the cross bracing in place in the notches provided just aft of the
ribs mid section. The cross braces are located within the respective rib lightening hole on the cut wood sheets.
Copyright 2005 Stevens AeroModel

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Copyright 2005 Stevens AeroModel

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4. Build the Landing Gear Block: Test fit and assemble LG1, LG2, LG3, LG4, LG5, and LG6 (See Illustrations).
Once satisfied with assembly align over plans and secure with thin CA.
LG6
LG4
LG1
LG2
LG3
LG5
(Note! The center section leading edge has undergone a slight modification to easy assembly of the wing center
locating dowels. The photos/drawings below may not reflect the exact shape of each part but the assembly remains
identical - this will be updated in a future release of this manual available for download at www.stevensaero.com)
5. Build Landing Gear Brace: Using a pair of 1/8” drill bits or the provided 1/8” wing dowels align LG7 on top of
LG8 through 1/8” alignment holes. Laminate LG7 to LG8 (ply) with thin CA. Allow to dry completely. Do not
glue the second LG8 (ply) part at this time.
LG7
LG8
LG8
6. LG7 is made from 3/32” Balsa – which due to variances from the balsa supplier is not always 3/32” thick – most
often it is slightly thicker than 3/32”. To ensure that the completed landing gear slides into the gear brace with
minimum effort you will want to test fit the second LG8 (ply) part to the landing gear brace assembly. Slide the
landing gear brace assembly inside the landing gear block slot about ¼” (Do not press it all the way in).
There should be some friction – but the fit should not be overly snug (remember you may want to remove the
landing gear from the wing at some point). If the fit is too snug sand the 3/32” balsa piece down and test the fit
once again. Repeat until the block slides in with minimal friction.
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7. Complete the landing gear brace by bending the 3/32” music wire gear legs as indicated on the plan sheet.
Nest the gear legs into the block then run thin CA over the boundary between the gear legs and the balsa.
Next, laminate LG8 over the assembly using the 1/8” drill bits to jig the fit. Drip thin CA into joint where gear
legs exit the landing gear brace. Allow gear brace assembly to dry completely then once again test the fit in
the gear block. Sand as required for a snug but smooth fit.
8. Mount Landing Gear Block: Align landing gear block between ribs R1 and wing spar – Snug the parts into
position and glue. Go slow here and match all edges of the assembly to the wing.
9. Double center joint of Wing Spar with S3 opposite landing gear block.
10. Test assemble W6, W7, and W8 (reference photo and plans for fitment of W8 to W6 and W7) then glue to the
main spar and rib R3.
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11. Fit parts W1, W1A, and W2 to wing aligning ribs over plan sheet but do not glue at this time. W1A sets the
spacing between ribs R1 and R2. W2 sets the trailing edge spacing of the remaining ribs (Note W2 is pre
slotted for CA Hinges).
W2 W1
W1A
12. Once satisfied wit the fit make sure the wing is resting upside down on table and all rib jigs are flat with table
surface. Glue W1, W1A, and W2 to wing assembly. Sand W1 flush with inside surface of R1 and outside
surface of R6.
13. Install W1B and W1C in position between ribs R1 and R1.
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14. Place wing upside down on flat surface – Laminate W3 to W4 to create the trailing edge. A 1/8” drill bit or the
1/8” wing dowels may be inserted into the alignment holes to ensure a true assembly. Key the trailing edge to
the underside of the wing – the plywood should be on the underside of the wing.
W4
W3
(note: The photo shows an older style W3/W4 trailing edge. )
15. Locate parts LE1 and LE2. Fit LE1 into recess spanning the center section parts LG4 and LG5. Parts LG5
should fit next to, but not interfere with, the 1/8” holes cut in the LE1 and LE2 pieces. Double LE1 with LE2
laminate the parts together with thin CA. Lay in 1/4” square leading edge stock (3/16” Square S300-SPT)
starting at R1 continue through R6 on both the right and left wing sections being mindful of matching the
alignment of the ribs to the plan sheet.
LE1
LE2
16. Install 1/8” x 3/32” turbulators (located on the 3/32” balsa sheet) in slots provided in top and bottom of ribs.
17. Finnish wing assembly by carefully removing alignment jigs/risers from tops of wing ribs – cut / sand turbulators
and leading edge flush with ends of wing - sand leading edge round to shape of airfoil and sand/taper the center
section leading edge to achieve a flush fit with the fuselage.
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18. Install wing center locating dowels. Prior to installing the wing center locating dowels you must shape the
leading edge as required in the previous step. Using the plan sheet as a guide verify/cut one of the provided
1/8” short Dowel rods to a length of 1-1/4”. Insert dowels through leading edge and into part LG1 DO NOT
GLUE AT THIS TIME. Test fit the landing gear block into slot in bottom of wing. The wing-retaining dowels
should nest into LG1 and not interfere with the landing gear block. Next test-fit the wing assembly into the
Fuselage former F2. Once satisfied with the fit CA the dowels to the Leading edge – remove the landing gear
block and CA the dowels into LG1, LE1/LE2, and the adjacent LG5 parts. Harden the mount points in Fuselage
Former F2 with thin CA.
R1
S3 (1/16" Balsa)
R1
Wing Allignment Dowel(s) 1/8" x 1.25"
(nests into LG1 but not into gap created by LG1 and LG2)
LG1
LG2
LG4
LG5LG5 LG5
LG6 LG6 LG6
LG4
LE1
LE2
LG1
Wing-Locating Dowels
Nest Here (But do not
extend into gear block
slot).
19. Build ailerons over plan sheet from 1/4” square stock and parts A1 (1/8”), A4 (1/16”), and A3 (1/16”) make a
right and left aileron. The remaining 1/4” square stock creates your hinge line. Refer to plan sheet for
location of aileron ribs. Do not glue A2 Control Horns in – this is done after covering.
Aileron Control Horn Assembly Detail.
A4 A5
A3
A4
p
A4
1
4" Sq.
Leading
Edge
A2
A5
A1
A4
A5
A3
1
8" Stock
1
16" Stock
1/32" Plywood
A2
Control
Horns
Copyright 2005 Stevens AeroModel