Stevens Aero Model FREDe 1.5X User manual

FREDe 1.5X
A ToonSCALEtm Park Flyer by Stevens AeroModel
Length 35 inches | Span 41 inches | Wing Area 580 inches2| Flying Weight 31 oz.
Last Revised 12/31/2010
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 1 of 38

Product Support
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 2 of 38
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 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.
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 on-line at www.stevensaero.com.
Stevens AeroModel
PO Box 15347 - Colorado Springs, CO 80935 - USA
719-387-4187 - www.stevensaero.com

Project Checklist
Kit Contents
Major Components
☐Laser cut wood (23 Sheets - See inventory on following pages)
☐Illustrated instruction manual
☐Pre-Cut Color Pilot (Left and Right) and Instrument Panel Sheets
☐1 - Pre-bent landing gear (1/8 in. dia. Wire)
Strip Wood
☐1 - 3/8 in. square x 36 in. balsa stock (Leading Edge)
☐2 - 1/4 in. square x 36 in. balsa stock (Main Spar Cap Strips)
☐3 - 3/16 in. square x 36 in. balsa stock (Turbulator Spars)
☐2 - 3/32 in. x 3/16 in. x 36 in. balsa stock (Sub Spars)
Long Hardware
☐1 - 12 in. Length 0.047 Wire
☐2 - 18 in. Lengths 1/32 in. Wire
☐2 - 14 in. Lengths 0.090 OD Nylon Tubing [27830]
☐4 - Basswood Wing Struts (Vertical)
☐2 - Basswood Wing Struts (Diagonal)
4x6 Hardware Bag
☐1 - 2-3/8 in. Length Hardwood Landing Gear Block [SIGSH655]
☐1 - Pair Micro Razor Control Horns [DUB936]
☐1 - Pair Mini E/Z connector [DUB845]
☐1 - Pkg. (4) 1/8 in. Wheel Collars [DUB139]
☐1 - 4-1/2 in. Length of 3/16 in. dia. hardwood dowel
☐1 - 6 in. Length 3/32 in. OD Aluminum Tube
☐1 - 6 in. Length 1/8 in. OD Aluminum Tube
☐2 - Micro EZ-Link [26310]
☐2 - 3-1/4 in. length 0.075 in. dia. wire.
☐6 - #32 Rubber Bands
☐8 - CA Hinges
3x3 Hardware Bag
☐1 - 3/4 in. dia. tail wheel.
☐1 - 1 in. length of silicone fuel tubing (EZ-Link Keepers)
☐2 - Rubber Retainers (Wing Pin)
☐4 - #8 Nylon Bushing
☐4 - 3/16 in. dia. Neo. Magnets
☐4 - 4-40 Blind Nuts
☐4 - 4-40 x 3/8 in. Bolts
Required Electronics (Available at StevensAero.com)
☐3+ Channel radio and micro receiver. We suggest the Spektrum DX6i and AR500 receiver.
☐2 - Hitec HS-81/82 class servos [HRC32082S]
☐SA Sport BL.10 Motor [SUPA2814-8] and APC 12 x 6SF Propeller [APC12060SF]
☐SA Sport - 30 Amp ESC [SUP30AESC]
☐Hyperion G3 7.4V 2100mAh 2 cell LiPo Battery [HP-LG325-2100-2s]
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 3 of 38

Project Checklist Continued
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 4 of 38
Building Supplies and Tools
☐1 oz. Medium CA Glue
☐1 oz. Thick CA Glue
☐1 oz. Thin CA Glue
☐CA glue accelerator (kicker)
☐CA glue de-bonder
☐30 min. Epoxy
☐Rubbing Alcohol (Epoxy Clean-up)
☐Balsa filler
☐Hobby Knife with ample supply of #11 blades
☐Sanding block with 400 and 600 grit paper
☐Heat Gun and Covering Iron
☐Small Needle Nose Pliers
☐Wire Cutters
☐Small Round “Rat-Tail” file
☐2.5mm Hex Head Wrench
☐Small Hammer
☐Scissors
☐ZONA 4 in 1 Saw Set [ZON35251]
☐DUBRO Hinge Slotter Kit [DUB660]
☐24 in. Straight Edge
☐Selection of Small Drills and Screwdrivers
☐Two 1/8 in drill bits.
☐1 in. x 12 in. length sticky back velcro
☐3/4 in. wide clear tape
☐3 Rolls AeroFilm Covering
☐1 Roll AeroTRIM Self-Adhesive Trim
☐1 Trexler Inflating Pump
☐Paper Towels
☐Enamel Paint Marker - Black [TES2547C]
☐Long sanding bar
☐Razor Plane
☐Small Spring Loaded Clamps
☐Low Tack Painters Masking Tape
☐3M 77 or Glue Stick for Profile Pilot
☐DEFT Clear Lacquer Spray

Laser Cut Parts Inventory
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 5 of 38

Laser Cut Parts Inventory
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 6 of 38

Laser Cut Parts Inventory
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 7 of 38

Laser Cut Parts Inventory
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 8 of 38

Laser Cut Parts Inventory
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 9 of 38

General Assembly Instructions
Thank you, for purchasing this Stevens AeroModel FREDe1.5X, a design inspired by the joy of flying.
This model 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, 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
intermediate model builder and “pilot”; we invite absolute beginners to correspond with us, or to seek the
help of another seasoned builder. 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. Promptly clean up any epoxy spills with rubbing alcohol and a disposable towel.
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 step(s) 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, always use medium CA glue for bonding parts.
Never force the fit!
Remember this is a precision cut kit our machines cut to within 1 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. Hey, dad always said it was easier to take
away material than add it back. With this in mind, should you find a joint or two to fit rather snug consider
lightly sanding 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 assembly.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 10 of 38

Wing Construction
☐Assemble center ribs from parts R1 (RIGHT)
and R1 (LEFT), W8a, W8b, W9a, and W9b.
☐Using 1/8 in. drill bits as alignment guides,
sandwich W8a between W8b and R1 (LEFT).
Align notches on all three parts. Ensure that
the etching on R1 (LEFT) faces up. Bond
with medium CA. Repeat for W9a and W9b,
creating front and rear strut sockets.
☐Repeat for R1 (RIGHT), ensuring that etching
on R1 faces up during assembly, creating
mirrored right and left center ribs.
☐Using a straight edge as a guide, assemble
lower spar jig W2 from parts W2a, W2b and
W2c. Bond with medium CA.
☐Install ribs R1 (sockets must face the wing
center as illustrated) at center notched
positions of lower spar jig W2. When fitting
W2 to wing ribs place one length of 1/4 in.
square balsa stock centered to W2 to forming
the lower spar cap strip. Tack glue parts at
corners where ribs interface spar to retain.
Note: Due to under camber in airfoil it will be
required to locate the spar to the ribs with the
forward portion of the ribs hanging off the
edge of your work table.
1/4 in. sq. balsa stock forms lower spar cap.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 11 of 38

Wing Construction Cont.
☐Using a straight edge as a guide, assemble
W4 trailing edge from parts W4a, W4b, and
W4c. Bond with medium CA.
☐Bond two each W6 gussets to square trailing
edge to ribs R1.
☐Tack glue ribs R4 to outside notches at trailing
edge and W2 lower spar jig.
☐Bond two each W6 gussets to square trailing
edge to ribs R4.
☐Fill in remaining ribs R2 and R3 and tack glue
at corners where rib interfaces lower spar and
trailing edge.
☐Using a straight edge, assemble upper spar
jig W1 from parts W1a, W1b, and W1c. Bond
with medium CA.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 12 of 38

Wing Construction Cont.
☐Fit upper spar jig W1 to span ribs. When
fitting W1 to span wing ribs, place one length
of 1/4 in. square balsa stock on top of and
centered to W1, forming the upper spar cap
strip. Tack glue parts at corners where ribs
interface spar to retain.
☐Install 3/32 in x 3/16 in. balsa spars through
holes in ribs aft of main spar. Allow ends of
sub spar to overhang assembly at R4, do not
trim and do not glue to retain at this time.
☐With wing assembly held flat to work surface.
Fit and bond center sub-spar shear web
SW10 between center ribs R1 to aft side of
balsa sub-spars.
☐Install remaining sub-spar shear webs SW11,
SW12, and SW13 to aft side of sub spars
between rib pairs R1/R2, R2/R3, and R3/R4
respectively.
Note the grain direction of SW11, SW12, and
SW13 runs at 45 degrees, alternate grain
direction of parts as illustrated.
☐Bond vertical grain shear webbing SW1
between spar caps and against forward
surface of W1/W2 spar jig at wing center.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 13 of 38

Wing Construction Cont.
☐Dry-fit W7 through slot in center of sub-rib
R1a - DO NOT BOND ANY PORTION OF
W7 TO WING SPAR OR SUB RIB AT THIS
TIME. Tack glue the dry-fit assembly of W7/
R1a to wing at notches in W1/W2 spar jig
where R1a sub rib interfaces.
☐Tack glue remaining sub-ribs R2a and R3a to
the wing assembly.
☐With wing held flat on top of work surface, fit
and bond the remaining vertical grain shear
webbing in the following order SW2, SW3,
SW4, SW5, SW6, and SW7 against forward
surface of W1/W2 spar jig.
Begin with SW2 and bond between rib R1
and R1a sub-rib. Next SW3 between R1a
and R2. Continue in this manner to complete
installation with SW7 being installed between
R3a and R4.
Again, do not bond W7 (from previous
assembly step) to any portion of the wing
assembly at this time.
☐Using a straight edge as a guide, assemble
the W3 jigged turbulator spar from parts W3a,
W3b, and W3c. Bond with medium CA.
☐Fit and bond jigged turbulator spar to forward
notch in ribs and sub ribs. Turbulator should
fit flush with ribs at wing tips and sit 1/8 in.
proud of the top surface of all interior ribs.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 14 of 38
No Glue!
No Glue!
R1
R1
R2

Wing Construction Cont.
☐Fit and bond remaining top and bottom
turbulator spars using 3/16 in. square balsa
stock. Again, turbulator spars will fit flush with
ribs at wing tips and 1/8 in. proud of the top
surface of all interior ribs.
☐Fit and bond 3/8 in. square balsa stock to
notch at leading edge of ribs and sub ribs.
When installing leading edge, W7 is captured
diagonally between R1 and leading edge and
R2 and spar as illustrated. With wing held flat
on top of your work surface bond W7 where it
contacts leading edge and spar.
☐Trim leading edge, turbulators, spar caps, and
sub-spar stock flush with outside edge of R4.
☐Invert wing then fit and bond rib cap strips
W10 to trailing edge at ribs R2 and R3.
☐Assemble two W5 wing tips from parts W5a,
W5b, W5c, and W5d. Bond with medium CA.
☐Bond W5 wing tips into slots at rib R4,
aligning front with center of L.E.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 15 of 38
Bond

Wing Construction Cont.
☐With wing held flat on top of your work
surface re-visit all tack glued wing joints with
medium CA.
☐With a razor plane and sanding bar, shape
L.E. to match profile on plan. Sand contour
smooth on wing tips and round off edges.
Leave trailing edge square.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 16 of 38

Fuselage Construction
☐Assemble fuselage crutch. Begin by inserting
ply F00 crutch through ply former F2, fitting
F2 into slots in F00 as illustrated.
☐Square F2 to F00 and tack with medium CA.
☐Locate 4-40 blind nuts to holes in ply firewall
F1. With a hammer, seat nuts firmly in F1.
Secure with medium CA around edge of nuts.
☐Dry fit F1 to tab on F00, orienting as shown..
Ensure that blind nuts are on the back of F1.
DO NOT GLUE F1 TO ASSEMBLY!
☐Fit balsa former F3 to top of F00 as shown,
with etching facing rearward. Square and
tack with medium CA.
☐Fit former F4 to F00 as shown. Square and
tack with medium CA.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 17 of 38

Fuselage Construction Cont.
☐Make right and left fuselage sides.
On a flat building surface, bond forward
fuselage sides from parts FSa, FSb, and FSc.
Bond FSd and FSe to forward assembly.
Bond truss parts to fuselage side assembly.
match tabs A with slots A.
☐Bond right and left fuselage doublers from
parts F0a, F0b, and F0c.
☐Fit one fuselage doubler to crutch assembly
and tack glue with thin CA.
NOTE - when properly installed, tabs on F1
and F2 will protrude through fuselage doubler.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 18 of 38

Fuselage Construction Cont.
☐Fit fuselage side to crutch/doubler assembly.
Tack glue at tabs with thin CA.
☐Fit and bond F4a through slots in F4 and
fuselage doubler.
☐Fit and bond ply F1b firewall doubler to front
of F1, aligning holes over blind nuts. Do not
allow glue to contact threads in blind nuts.
☐Fit and bond cross grain doubler F1a to inside
of fuselage forward of F1b plywood doubler.
☐Fit F1c behind F1 and above F00. Bond with
medium CA.
☐Fit SR1 below F00 and in front of F4. Bond
with medium CA.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 19 of 38

Fuselage Construction Cont.
☐Fit and bond cross grain doubler F3a to
fuselage side above F00 and in front of F3.
☐Fit and bond F3b to fuselage side above F00
using medium CA glue.
☐Fit remaining fuselage doubler to crutch
assembly. Tack with thin CA.
☐Dry fit F5 to fuselage side. Do not glue.
☐Fit remaining fuselage side to crutch/doubler
assembly. Square assembly on flat surface
and bond all joints forward of former F4.
☐Pull fuselage sides together at F5 and tack
with thin CA.
FREDe1.5X © 2010 Stevens AeroModel all rights reserved. Page 20 of 38