Stevens Aero Model CAP 232 User manual

© 2003 Stevens AeroModel Page 1 5/8/2008
CAP 232
1:12 Scale micro
V2.01
Span 24.2” / Length 22.2” / Area 105 Sq.” / Weight 6-7oz

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REQUIRED TO COMPLETE KIT
Kit Contents:
¾Computer Drawn Rolled Plan Sheet
¾Illustrated Instruction Manual
¾1 - Clear Canopy
¾1 - Cowl Assembly
¾Bricked Wood and Wire/Tube Stock
Laser Cut Balsa and Hardwood Parts (See Parts Inventory Sheet)
2 - 1/32” x 12” Music Wire.
1 - 12” Length of pull/pull guide tubing.
2 - 3/16” Square x 18” balsa stock
2 - 3/16” Square x 12” balsa stock
¾Hardware Bag (4x6 Bag)
2 - 1/8” x 3” hardwood wing dowel (Wing Hold Down)
1 - 1/8” x 2” hardwood wing dowel.
1 - 1/4” x 3” hardwood dowel (LPS Motor Mount)
2 - 0.070” x 3” length carbon rod (Landing Gear Struts)
1 - 1/16” x 3” length heat shrink tubing.
1 - 1/16” x 4” aluminum tube.
2 - 1”x3/4” CA Hinges
1 - Package #16 rubber bands.
Suggested Finishing Items:
¾DuBro RC 1” Mini lite wheels (DUB100MW).
¾DuBro RC Micro Pull/Pull Assembly (DUB846).
¾1 Roll Stevens AeroModel AeroLITE film
Suggested Radio Gear:
Note that the Micro Cap 232 was originally designed for brushed power systems. The design lends itself
very well to brushless power. When running a brushless system shoot for a motor that turns a 6-7” propeller
with authority while producing about 45-60 Watts. This should be ample power for the micro Cap 232.
Small hand wound CD Rom motors and similar outrunners readily attach to the motor stick and are capable
of the required power output. New light weight servos can also be used in place of the GWS Pico servos -
Cirrus CS101’s work great and only require minor fit modifications.
¾3 - GWS Pico Servos (GWSPIC/STD/J)
¾1 - Sub-micro Receiver 6g or less (Berg MS4L)
¾1 - 2A ESC (GWESC050A)
¾1 - LPS-RLC-C 4.8v (6.0:1)
¾1 - Motor Heat Sink (GW/EHS-50)
¾1 - 7x6 Slow-Fly Prop (GW/EP7060)
¾1 - 7.4V 350mAh or smaller LiPo battery (ThunderPower RC Pro-Lite 350mAh)
Things you may need:
¾Thin CA (super glue)
¾CA Glue Tips
¾Five Minute Epoxy
¾Plastic Model Cement
¾Clear Plastic Wrap (for protecting plans)
¾Razor Blade(s)
¾Fine Grit Sand Paper
¾Flat Rat Tail File or Emery Board
¾Clear Tape
¾Balsa Wood Filler
¾Sewing Thread

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GENERAL ASSEMBLY INSTRUCTIONS:
Thank you, for purchasing this Stevens AeroModel 1:12 Scale Cap 232 (MICRO).
Please keep in mind that while small and cute like a “park flyer” this is a sport plane and behaves as such.
Therefore we recommend this kit to the advanced pilot. The tiny airframe, wheels, and building materials
exclude this model from flying from anything but and improved surface (read: sealed asphalt, concrete,
etc..). A good rule of thumb –if you cannot readily taxi and take off from the surface – do not attempt to land
there!
We hope you enjoy this model as much as we have.
Sincerely,
Bill Stevens
Stevens AeroModel
1528 S. Nevada Ave.
Colorado Springs, CO 80906
[email protected]
General Assembly Tips
READ THE INSTRUCTIONS and the plan sheet prior to starting any work!
Tape plans to work table. Cover with wax paper or plastic wrap.
Join all joints with Thin CA unless otherwise specified.
DO NOT REMOVE THE PARTS FROM THE BALSA SHEETS UNTIL REQUIRED!
DO NOT FORCE THE FIT – when in doubt double check your parts and remove 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, referenced each piece against the plan sheet.
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.
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 3/32” balsa sheet. Work with each component
separately. Assemble over plan sheet, removing only those parts necessary to complete each
individual component. Though the parts fall together and self jig, pay particular attention to making
solid glue joints. (note: at the time of printing your plan sheet may reflect the old-style tail feathers
use the included update sheet to replace the parts overlay for the tail feathers as illustrated on the
plan sheet)
F
Elevator
Horizontal
Stab.
D
A
D
A
EE
BB
C
F
C
FF
CC
E
E
BB
DDVertical
Stab.
F
F
I
I
E
E
G
G
H
H
2. Elevator Joining Tube. Locate the provided 1/16” aluminum tube - rough the surface with fine grit
sand paper to remove dirt, oil, and debris, from the tube. Bond elevator halves over plan sheet
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 sandpaper and bevel / taper hinged surfaces in preparation for your
preferred hinging method.
Fuselage
Fuselage components are exceptionally brittle until the entire assembly is complete. Handle parts
accordingly and do not force the fit!
1. Join over plan sheet F16A and F16B to produce 2 F16 fuselage side sheets.

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2. Assemble formers F4, F5, and F6. Join over plan sheet F4A, F4B, F4C, F4D, F5A, F5B, F5C,
F5D, F6A, F6B, F6C.
3. Assemble fuselage sides over plan sheet. Parts are grouped on the 3/32” balsa sheet. Make 2
sides.
4. Locate Firewall parts F1 and F2 – if using the recommended LPS drive insert the 10mm balsa
square with the ¼” hole into both F1 and F2 (Hole should be positioned such that it is at the lower
part of the square when joined to F1/F2. Join fuselage sides to F1, F2 and F1A. Test fit parts
before gluing.
F1 F2
F1A
LPS Adapterx2

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5. Install F3A, F3B and servo rails SR1-SR2. Site fuselage construction over plan sheet top view to
ensure straight and true assembly. Join each of these to the fuselage sides in their respective
positions. Note the servo rails are composed of a top piece SR1 and bottom 3/32” doublers SR2.
6. Glue F14 3/32” stringers to top of F1, F2, and F3A.
1. Pinch fuselage sides together at tail position, using a flat rat tail file or emery board bevel the
notches and alignment tabs in the fuselage to better accommodate formers F4, F5, and F6.

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2. 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!
3. Proceed to install former F5 and F6 inserting F13 stringer along the bottom of the formers to jig the
assembly. Initially test fit F5 and F6 then glue F5 and F6 to fuselage sides - then glue (if the fit is
too snug bevel the notches with a rat-tail file or emery board). Only glue F13 where it makes
contact with F4, F5, and F6 – Do not glue F13 to fuselage sides at this time!
4. Test fit former F7. Capture aft section of F13 between fuselage sides, do not glue at this time.

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5. 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.
6. Add tail gear block F11 to aft section of F13 inside fuselage.
7. Laminate F10 in position over aft section of fuselage. Important - Key F10 to top of F7.

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8. Laminate F9 to F10, key to F7. DO NOT align with holes provided in F10 but key to F7.
9. Test fit F12 to F8. Lay F8 on building table, press F12 into F8 and glue.
10. Test F12/F8 assembly to formers F4, F5, and F6 (do not glue until specified). Align outer edge of
F8 with outer edge of F9 and tack glue just the aft end of both parts.

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11. 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
12. Glue F12/F8 assembly to F4 and F5.
13. Laminate finishing blocks to top of F8.
14. Sheet fuselage sides with F16.
15. Sheet fuselage top/front with F17. 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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16. Key F3C to fuselage and glue to F4.
17. Prior to sheeting turtle deck, route included elevator and rudder pull / pull guide tubing. Run a short
length of tube for the elevator (it doesn’t matter what side you run it out of) flush with F3C and
secure through hole in one side of F5 (leave about 1/8” beyond F5) where your elevator pull / pull
cable will exit through turtle deck. The remainder of the pull/pull tube should be installed flush with
F3C and extend through the elongated slot in F13 approximately 3/8” below fuselage. Secure
Pull/Pull tubing with a small dab of thin CA then create fillets of 5-Minute epoxy at each plastic to
balsa joint.
18. Sheet the Turtle Deck with F18 (It helps to pre-sand the turtle deck slightly) Try to sheet the turtle
deck dry – as a last resort use rubbing alcohol to soften wood and facilitate bending around the
radius of the turtle deck. Test fit – then secure one end with thin CA. Next, gradually tack down
the sheets to the formers with thick CA. Glue to formers F6, F5, and F4. Glue to F3C. Finally, trim
and sand leading edge of turtle deck sheeting flush with F3C.

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19. Carve and sand aft section of turtle deck round.
20. Battery Tray: Install the battery tray (located on the 1/16” balsa sheet and designated as “Battery
Tray”) inside the fuselage spanning formers F2, F3a, running span-wise along the stringers F14.
BATTERY TRAY
21. Verify length and sand the ¼” motor mount dowel to achieve a snug fit with the appropriate cut outs
in fuselage formers F1 / F2. Prior to installing in fuselage - the dowel must be turned down to fit
the LPS drive – to do this chuck the dowel into a power drill and sand off material reducing the
diameter of the dowel to fit snug with the LPS drive. You only need to reduce 1” of the dowels
diameter and must leave the remainder of the dowel ¼” in diameter to properly fit within the firewall
mounts F1 and F2. Be certain to test fit the motor mount stick to the LPS Gearbox –install motor
mount through formers (don’t force the fit) and secure with thin CA. Support the backside of the
motor mount stick when sliding the IPS gearbox on or off the mount! The fuselage firewall will also
accommodate the following drive systems – Astro 010 Direct Drive / GWS IPS Motor – Gearbox /
GWS EPS Motor – Gearbox. We have found the 4.8v LPS Drive / Direct Drive Astro 010 to net the
best performance and highly recommend the 4.8v LPS Drive as the all around best fit for this
airframe.
F1 F2
LPS Adapter: Support added for LPS drives via LPS
adapter plug. To fit LPS drives simply sand down one side
of a length of 1
4" dowl to fit the drive gearbox and insert
un-sanded 1
4" dowel through firewall using LPSadapter.
Support added for direct
drive AstroFlight 010
motors.
Allows the use of two
1/8" dowels (not
supplied with the kit) to
mount a direct drive
Astro 010 BL motor.
Insert two 1
8" dowels of
the appropriate length
(use rolled plan sheet)
through firewall and
strap Astro 010 to
dowels.

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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.
2. Key R1, R2, R3, R4, R5 and R6 onto main spar. Align over plan sheet upside down and glue.
3. Build up landing gear block as shown on plan sheet. Laminate LG3A and LG3B to LG1 – Finish the
assembly by laminating the LG2 over LG3A and LG3B opposite LG1.

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4. Test fit and assemble LG4, LG5, and LG6 to landing gear block. PAY ATTENTION to the location
of the landing gear slots – the landing gear slots narrow at the top and are spread apart the furthest
at the bottom. Once satisfied with assembly align over plans and secure with thin CA.
LG4
LG4 LG5
LG6
LG5
LG6
LG5
LG6
5. Align landing gear block between ribs R1 and wing spar – Snug the parts into position and glue.
6. Double Wing Spar with S3 opposite landing gear block.

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7. Fit parts W1, W2, and W3 to wing aligning ribs over plan sheet but do not glue at this time. W2
sets the spacing between ribs R1 and R2. W3 sets the trailing edge spacing of the remaining ribs.
8. Once satisfied with the fit make sure the wing is resting upside down on table and all rib jigs are flat
with table surface. Glue W1, W2, and W3 to wing assembly. Sand W1 flush with inside surface of
R1 and outside surface of R2.

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9. LE1 keys to the gear block parts LG5 and LE2 is laminated to LE1. LE1 and LE2 have two 1/8”
holes bored through them to receive two 3/8” lengths of 1/8” dowel (cut from the 2” length of 1/8”
dowe stock) and function to center the wing to the fuselage (these are non structural and not
designed to handle in-flight loads without the use of rubber bands to mount the wing). Follow the
diagram below for positioning information for LE1 and LE2. Install each 3/8” length of 1/8” dowel
only after you have shaped the leading edge and covered the wing.
R1
LE1
LE2
LE1
LE2
LG5 LG5 LG5
Wing center locating dowels.
Cut a 3/8" length of 1/8" OD
Dowel and insert into wing
leading edge after covering.
Once LE1 and LE2 have been installed to the wing center section, align wing assembly over plan
set matching the rib locations of the wing to that of the plans. Next, locate the two 18” lengths of
3/16” square balsa stock and install these spanning ribs R1 through R6 as illustrated on the plan
set. Finally Trim the leading edge stock flush with the outside edge of rib R6.
10. Remove the 1/16” x 3/32” turbulators from the 1/6” parts sheet – Install turbulators to wing using
groves provided in ribs.
11. Laminate the W7 pieces together in pairs of two to create the aileron servo block.
12. Sand to fit and slide into provided holes on ribs R1 – Remember your orientation! – do not glue
servo block in upside down.

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13. With wing upside down on flat surface, slide W4 into position to create trailing edge of wing -
double bottom of W4 with W5 (1/32” ply on underside of wing trailing edge).
W5
W4
W5
14. Locate the torque rod holes in R1 and R2 - harden the wood around the holes using thin CA. Run
a small length of 1/32” music wire through each hole to verify that the torque rods, once installed,
will move freely. If using the Dubro Micro Aileron System now is the time to install the torque tube
sleeves by enlarging the holes to fit the poly tubing.

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15. Build ailerons using parts A1 and A2 reference plan sheet for positioning– make a right and left
aileron. Friction fit all parts together, prior to committing with glue, making a right and left side over
the plan sheet then add the 3/16” aileron leading edge which creates your hinge line – go slowly
and makes sure not to twist or warp the aileron.
A1
A1
A1
A1
A1
A1 A1
A1 A1
A1
A2
A2
The inside rib bay of the ailerons will form the torque rod block and requires laminating part A4 – to
the innermost A1 aileron rib then laminating A3 to A4 creating the inside edge of the aileron.
Remember create a right and left side. Nest a 3/8” length of poly tubing within the gap created by
A4/A3 – this tube allows for solid control of the aileron and minimizes binding – do not leave this
tube out! See detail below to get a better idea of how the aileron torque rod assembly functions.
A4
A3
W1
A1
A3
A4
W2
W7
W7
W4
Heat Shrink
Tube
W5 Doubles
W4 Underside
of Wing
Note: Nest a 3
8" length of
1/32" ID tubing insidepocket
created by the laminationof
parts A1, A3, and A4. This
will act as a bearing forthe
torque rod and prevent
binding.

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Landing Gear
The carbon landing gear supplied with this kit offers great strength and keeps the weight to a minimum.
However, sharp/abrupt impacts with the ground may cause the gear to snap exploiting a weak spot in the
carbon rod (a nick or razor cut will create a weak spot). If you are not concerned about counting every gram
(or plan on exceeding the maximum recommended AUW of 8 oz) you may wish to substitute a more durable
but heavier 1/16” music wire gear in place of the carbon composite.
1. Cut or Verify that 0.070” carbon rod is cut to appropriate size. Sand at least 1” along ends of
carbon rod with fine grit sand paper to facilitate bonding when glued.
2. Bend 1/32” music wire as outlined on plan sheet sand bond area of music wire with fine grit paper
and lash to carbon rod with thread. Soak threads with CA glue.
3. Laminate balsa to create a right and left wheel pant – refer to plan sheet. Sand to desired shape.
Note the groove in the outside of the wheel pant to capture the axle. Laminate parts in the
following sequence WP1 – WP2 WP3 – WP3 – WP3 – WP4. Reverse sequence to create opposite
wheel pant.
4. Slide wheel pant partially onto music wire axle – Slide 1” Dubro Mini-Lite wheel onto axle –
continue to slide wheel pant onto axle. Nest the axle in the side groove of the wheel pant and
secure with a thin bead of epoxy. Place a dab of epoxy on the outer most portion of the axle where
it comes in contact with the wheel pant.
5. Slide completed landing gear into landing gear block in wing check the fit and alignment – remove
then re install with a smear of 5-min. epoxy – do not use CA as it will make the gear brittle.
6. Using plan sheet as a reference, bend a length of 1/32” music wire as indicated to create a tail skid
– install optional tail gear block and wheel if so desired.
Canopy/Cowl
1. Trim canopy to fit – a scribe line on the molded part is provided to assist with this task.
2. The cowl assembles in two pieces one nesting inside the other along a grove in the molded parts.
Carefully trim each part and test assemble cowl to fuselage. When satisfied with fit, bond parts
with liquid model cement fill seam and paint to match color scheme of model. Cut out vent holes in
cowl to provide cool air to motor. IMPORTANT! Only use liquid model cement on cowl CA will
cause the plastic to become brittle. Additionally, when painting the cowl start with a light mist of
primer – then build up your paint in light coats allowing each layer to dry completely before applying
the second coat. APPLYING PAINT TO THICK WILL MELT AND DEFORM THE STYRENE – we
recommend Testors® brand model paint.

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Final Assembly
1. Cover and trim the entire model with AeroLITE. Caution heavier covering materials will crush the
structure.
2. Cut provided CA hinge material into small strips (as illustrated on plan sheet).
3. Determine hinge points for control surfaces (use the plan sheet as a guide) then pre-slot elevator,
rudder, and wing assemblies at hinge points to accept CA hinges.
4. Sand ends of wing dowel smooth then insert wing retaining dowel rods into holes provided in
fuselage – secure dowels with thin CA.
5. Complete the install of wing centering dowels from step 9 of “Wing” instructions.
6. Slide elevator into slot within fuselage. Then, insert the horizontal stabilizer. Now, hinge elevator
to horizontal stabilizer - secure hinges with thin CA. Finally, center the stabilizer assembly and
align square to wing tips. Secure with thin CA.
7. Insert 1/32” ply control horn into horizontal stabilizer on the same side that your pull / pull guide
tube exits the turtle deck – secure with thin CA.
8. The vertical stabilizer keys into the aft section of the turtle deck and the groove in the aft end of the
fuselage. Carefully work the vertical stabilizer into place and secure with thin CA.
9. Fit CA hinges to rudder and vertical stabilizer – secure with thin CA. Insert 1/32” ply control horn
into ruder and secure with thin CA.
10. Using plan sheet as a guide – make up two aileron torque rods and two aileron push rods. Slide
torque rods through holes in R1/R2.
11. Test fit CA hinges to ailerons and wing – Fit torque rods to ailerons. Secure hinges and torque
rods to aileron with thin CA.
12. Install tail skid assembly by drilling a small hole in the aft end of the fuselage (reference plan sheet)
– secure skid with thin CA.
13. Install main gear – sand 1/16” carbon rod and feed into landing gear block – secure with a small
amount of Thin CA.
14. Fit / mount cowl and canopy to fuselage secure with clear tape. (Remember you may need to allow
for access to the canopy area for servo adjustment).
Radio Gear
1. Install (2) sub micro servos for your elevator and rudder control and (1) sub micro servo for your
aileron.
2. As illustrated on plan sheet, center ailerons and bend torque rods perpendicular to wing. Connect
aileron push rods to torque rods using the provided heat shrink tubing to create a flexible joint –
shrink tubing and secure ends of tube with thin CA.
3. Set up pull / pull linkage according to the guide included with the required Dubro DUB846
Hardware. Secure pull / pull crimps with thin CA in addition to crimping!
4. Mount battery with Velcro to top of wing forward of main spar.
5. Mount receiver with Velcro to underside of turtle deck.