Stevens Aero Model Free Flight HLG01 User manual

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© 2007 Stevens AeroModel. All Rights Reserved.
HLG01
Hand Launch Glider #1
Span 18 in. / Length 19-3/8 in. / Area 46.5 sq. in. / Typical Flying Weight 25g

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© 2007 Stevens AeroModel. All Rights Reserved.
WARRANTY
Stevens AeroModel guarantees this short 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.

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© 2007 Stevens AeroModel. All Rights Reserved.
General Information:
Thank you for purchasing this Free Flight kit by Stevens AeroModel. Please inspect your kit for
missing or damaged items. To complete this model you will require basic woodworking tools (a
sanding block and sand paper), thin CA glue, clear tape, a water, lacquer, or oil based wood
sealant.
Product Features:
•Simple construction with many building aids (jigs included in kit)
•Viscous Timer for Dethermalizer (DT) Included with model
•Ultra reliable pop-up fuselage DT design
•Durable balsa, ply, and hardwood construction with Carbon Fiber boom.
•Ballast pocket integrated into nose of glider.
•Outstanding performance ideal for entry-level competition use.
Kit Contents:
•Illustrated Instruction Manual and Trim Guide
•Laser cut sheet wood bundle.
oHLG01-0104 1/8” Med. Balsa
oHLG01-0204 1/32” Ply
oHLG01-0304 3/16” Med. Balsa
oHLG01-0404 1/16” Soft. Balsa
o13-1/4 in. Length of 1/8 in. diameter carbon tube
•Hardware Bag
o1 - Bag of clay ballast (~7g)
o1 - Bag of viscous putty for timer (~.07g)
o1 - 24in. length of abrasion resistant thread
o5 - #0 x 3/16 in. sheet metal screw
o3 - T-Pins 1” long
o1 - 1/14 in. length of 1/16 in. OD aluminum tubing
o1 - 2 mm ID rubber bushing
o1 - 1 in. length of .8mm dia. carbon rod
o1 - 1/8 in. aluminum pop-rivet body
o1 - 1/8 in. dia. hardwood dowel
o1 - 1/16 in. laser cut plywood bushing
o1 - assorted mini rubber bands
o1 - 1/8 in. laser cut hardwood fuselage pivot

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© 2007 Stevens AeroModel. All Rights Reserved.
Instructions for Assembly:
General Instruction
What follows is a brief overview of the steps taken to complete this model. Begin by shaping the
wing and dihedral breaks. Assemble the wing using the jig based construction then set aside
while the fuselage is constructed. With the fuselage complete you will assemble the stabilizer
components. With the major components built you will wrap the project up by joining the wing
and stabilizer to the fuselage add your finger rest and washout wedge then rig the DT line.
Tips for Success:
•Thoroughly read these instructions prior to commencing work on the model.
•To avoid loosing parts only remove a part from the laser cut sheet or parts bag when
instructed to use it in assembly.
•The model is bonded almost entirely from thin CA glue we highly recommend using an
extra fine glue tip to apply glue in a metered and precise fashion.
•Only commit a part with glue when you are absolutely satisfied that it has been installed
properly and you have been instructed to.
•Protect your building surface by using the bag this product came in as a non-stick barrier
for glue application.
•We continually make refinements to our product and our instructions. Visit
www.stevensaero.com and download the latest instruction manual for this product.
Parts Orientation:
When an instruction details a “right” or “left” side of the model this is always referenced from the
perspective of standing behind the aircraft looking at the top of the model with the models nose
pointing away from you.
Key terms:
Aft - at, close to, or toward the stern or tail
CG - center of gravity, the balance point of the model.
Dihedral - is the upward angle from horizontal in a fixed-wing aircraft or bird wing from root to tip,
as viewed from directly in front or behind the aircraft.
DT - dethermalizer
Fore - situated at or toward the front, as compared with something else.
Laminate - to construct from layers of material bonded together.
Leading Edge - the edge of an airfoil or propeller blade facing the direction of motion.
Polyhedral - Wings with local dihedral angles that change along the span.
Trailing Edge - the rear edge of a propeller blade or airfoil.
Tack Glue - to temporarily bond together using the minimum amount of glue to retain the part.
Wash-In - a warp in an airfoil that gives an increase in the angle of attack toward the tip.
Wash-Out - a warp in an airfoil that gives a decrease in the angle of attack toward the tip.
Special advice for Left-handed throwers:
The assembly instructions that follow illustrate building a glider for right-handed throwers. If you
are left-handed, or desire to throw left-handed, there will be certain steps where a component
should be assembled in reverse order. Please read the instructions carefully and take note
where we offer building advice for “Lefties!”.

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© 2007 Stevens AeroModel. All Rights Reserved.
Shaping the Wing
Remove the entire wing core from the 3/16”
balsa sheet. The wing features an etched
“high point” sanding guide on the top surface
and pre cut dihedral breaks. The dihedral
breaks are partially cut through and retained
with thick skip lines that run across the grain
DO NOT SEPARATE THE WING SECTIONS.
Begin by shaping the wing as one unit using a
sanding block and / or a razor plane to
produce a flat taper from the etched “high
point” aft to the trailing edge. Next round the
wing from the high point forward to the leading
edge. Use the sanding guide below as a
reference. We suggest leaving the trailing
edge 1/32” thick for maximum durability.
Round from high point forward Flat from high point aft
High Point Balance Point
(~ 1-3/4 in. from leading edge at root)
1/32 in. 1/32 in.
Airfoil Sanding Guide
Wing Assembly
1. Using a sharp blade separate the wing core into six total segments (three per side) by
cutting skip lines that retain the sections.

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© 2007 Stevens AeroModel. All Rights Reserved.
2. Assemble sanding jigs. From the 3/16” balsa stock assemble the parts to create the 5
degree jig (first photo) and two 10 degree jigs (second photo) as illustrated below.
3. Use the guide below to sand the appropriate angles at the wing center section and
breaks 1 and 2. An example is given for use of the jigs for sanding wing panel 1.
Complete remaining panels in the same fashion.
A = Sand edge using 5 degree jig.
B = Sand edge using 10 degree jig.
C = Sand edge using 10 degree jig.
ABBCC
Polyhedral Break Sanding Guide
Sand Perpendicular
to Building Board
Building Board 5 degree Jig
AB
Example (Given to complete panel 1)
Remove
Material
Sand Perpendicular
to Building Board
Building Board
10 degree Jig
A
BRemove
Material
Step 1 Sand "A"
Step 2 Sand "B"
Wing Center Section Break 1 Break 2
Wing Panel 1 Wing Panel 2 Wing Panel 3

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© 2007 Stevens AeroModel. All Rights Reserved.
4. Join the wing panels to create the polyhedral wing. Review diagram below before
proceeding to bond the wing.
B
B
C
A
C
20°
20°
A
10° Use 10 degree jig to set
wing center section
Wing Center Section Break 1
Stack two each 10 degree
jigs to set polyhedral break 1
Withwingpanel2flatonbuildingboard.
Stacktwoeach10degreejigstoset
polyhedral break2
Wing Panel 1
Break2
Lay right side wing panel 1 flat on top of building board. Use a 10 degree jig to block left
side wing panel 1 up at proper angle. Make certain that wing panels meet flush at wing
center section correct fit if required. Once proper fit has been achieved wick thin CA glue
along center section joint. Allow time for glue to cure then re-apply CA glue for a strong
joint.
Stack and glue two each of the 10 degree jigs to assemble one 20 degree jig and place
under wing panel 1. With wing panel 2 flat on top of building board glue to outer edge of
wing panel 1. Allow time for glue to cure then re-apply CA glue for a strong joint.
Repeat for opposite side.
Follow same process as above with assembled 20 degree jig under wing panel 2 and
wing panel 3 flat on top of building board to complete the polyhedral wing assembly.

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© 2007 Stevens AeroModel. All Rights Reserved.
5. Protect wing assembly by spraying a light coat of clear wood finish over wood surface.
We suggest any non-water based spray such as Lacquer or Urethane. Water based
Acrylic sprays may warp your wing!
Fuselage Assembly
1. Begin assembly by laying out the three major fuselage components we will refer to these
from left to right in the photo below. Notice that the major fuselage components
assemble to create the following: A pocket for ballast which is left open on the RIGHT
side of the glider. A cavity for timer media which is left open on the LEFT side of the
glider. Lefties! the fuselage parts layout order will need to be reversed to place the timer
media cavity on the right side of the glider. To build a left handed fuselage simply swap
the top and bottom plywood parts in the first photo set.

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© 2007 Stevens AeroModel. All Rights Reserved.
2. You have been given a length of 1/8” dowel, cut this dowel into two equal sections and
use to align the fuselage parts as illustrated. Laminate these parts together using thin CA
glue. With the fuselage components bonded together glue the 1/8” dowels within the
alignment holes then cut and sand flush with outside surface of fuselage.
3. Assemble the pop-up tail boom. Locate the 1/8” laser cut hardwood fuselage pivot in
your parts bag and 13-1/4” length of 1/8” diameter carbon tube. The carbon tube is
keyed to the pivot as illustrated in the first photo below. Lay both the carbon tube and the
pivot atop a flat surface and bond these parts using thin CA glue. Make multiple
applications of glue between the boom and pivot allowing ample time for the glue to cure
between applications.

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© 2007 Stevens AeroModel. All Rights Reserved.
4. With the pop-up tail boom assembled. Test fit the tail to the main fuselage assembly.
Locate the provided 1/8” aluminum rivet body and temporarily install through fuselage
and pivot as illustrated below. Note any significant friction that may interfere with the tail
smoothly rotating to near vertical within the fuselage and eliminate by evenly removing
thickness from the pivot and tail boom. Continue test and fit method until the tail rotates
with minimal friction when installed to the fuselage assembly. Caution: we do not want
the fit to be loose. Rotation should be free with no tendency to bind or grab yet not at the
expense of allowing side-side play in the pop-up tail boom assembly.
5. Final installation of your properly fit pop-up tail involves installing the 1/8” aluminum rivet
through the fuselage sides capturing the pop-up tail block and securing the rivet so that it
will not slip out in use. With the rivet head flush against the Left side of the fuselage use
your sanding block to reduce the Right side rivet overhang to 1/64” - 1/32” of overhang
beyond the ply fuselage side. Support the rivet head against your work table then from
the Right side place a #0 Phillips head screw driver centered within the rivet body.
Lightly tap the screw driver to flair the rivet body so that it will not slide back out of the
assembly. Note: being too aggressive with the flair will result in binding use the minimum
amount of force necessary to flair the rivet body. Finally apply a tiny drop of thin CA glue
at the to the surface where the outside edge of the rivet body and ply fuselage sides
meet.

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© 2007 Stevens AeroModel. All Rights Reserved.
6. Timer top assembly. Center the 1/16” ply bushing on 1/32” ply timer chamber top. Use
the ¼” x 1/16” OD aluminum tube to center the parts (first photo). Allow aluminum tube
to protrude beyond back side of 1/32” ply chamber by 1/64” (second photo). Secure
tube, ply bushing, and chamber to parts using thin CA glue. DO NOT ALLOW GLUE
WITHIN 1/16” aluminum tube.
7. Timer mechanism assembly. Insert 1” T-Pin through aluminum tube as illustrated (first
photo). With T-Pin bottomed out against back side of timer top assembly, grasp pin just
beyond where it extends out top of timer assembly and bend to 90 degrees (second
photo). Note: You’ll want your bend to be as close to the point at which pin exits
aluminum tube to reduce slop. Check to be certain your pin rotates freely within timer top
assembly and adjust to eliminate binding, if required (third photo).

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© 2007 Stevens AeroModel. All Rights Reserved.
8. Locate the 2mm id rubber bushing this part looks like a “top hat”. Using a 1” T-Pin make
a hole that measures 3/32” back from inside edge of rubber hat bushing (first photo).
Thread the needle that is installed to the timer top assembly through the hole you made
in the rubber bushing from the inside out (second photo). Then, slide bushing down on
aluminum shaft as illustrated (third photo). Use wire cutters to clip the remaining length
of T-Pin even with the outside edge of the timer top assembly (fourth photo).
9. Locate the 0.07g of viscous putty and load into timer cavity of fuselage assembly. Work
the putty in to where there are no air pockets then level with outer edge of fuselage as
illustrated.
10. With the putty installed within the timer cavity use four of the #0x3/16” sheet-metal
screws to secure the timer top assembly to the fuselage as illustrated below.

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© 2007 Stevens AeroModel. All Rights Reserved.
11. Install incidence adjustment screw. On the bottom of the fuselage assembly there are
two scalloped cuts about 3-1/4” forward of the aft most point on the main fuselage
assembly. Rotate the pop-up tail out of the fuselage assembly. Now, use a T-Pin to
mark the location on the balsa within the fuselage sides that is centered within these two
scallops and the fuselage sides. You will install the remaining #0x3/16” sheet metal
screw by threading it into the balsa at the point you just marked. Initially, thread this
screw into position then back out of hole completely. Place two small drops of thin CA
glue to hole/threads cut by the screw within the balsa. Allow CA to cure then re-install
screw being careful not to strip the now CA reinforced threaded hole.
12. Install DT string guide. Cut one of your T-Pins 1/8” from base of “T” as illustrated below
(save the remnant T-Pin metal for later use). Using a small blade or common-tip screw
driver slightly expand the loops that form the “T”. Test to make certain that DT thread
easily slides through loops in “T”. Next, center the “T” pin assembly within the slot
provided atop the fuselage assembly. Run this “T” down within slot allowing equal
amounts of the “T” to overhang fuselage sides and until seated flush with bottom of cut-
out. Secure the “T” within slot using CA glue. DO NOT ALLOW glue to fill loops of “T”
as this will prevent later installation of DT thread.
13. Pop-Up spring aft lug assembly. Using the remnant T-Pin metal from step 12 bend a
bend into “S” shape as illustrated below. Start the “S” about 3/16” from the tip of the pin
leaving the bottom of the “S” straight. Make the bends as tight as possible using small
needle nose pliers. Trim excess material off the end opposite the tip of the pin. Install
completed “S” centered to aft edge of pivot block as illustrated below. Glue.

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© 2007 Stevens AeroModel. All Rights Reserved.
Horizontal and Vertical Stabilizer
1. From the 1/16” soft balsa sheet remove the vertical stabilizer components and glue
together as illustrated (first photo). The top of the horizontal stabilizer has two etch lines
scribed down the center of the piece. Sand* the leading edge round for both the
horizontal and vertical stabilizers. Next, key the vertical stabilizer to the top of the
horizontal as illustrated (second photo). Verify that the vertical stabilizer has been
installed perpendicular to the horizontal then glue.
(*you are more than welcome to aggressively sand, taper, and otherwise airfoil the
stabilizer assembly. Any compromise in thickness will compromise strength if this is
your first HLG you may wish to leave the stabilizer thickness at the stock 1/16”. For
those more experienced we have chosen the 1/16” stock to allow you adequate material
to airfoil these parts.)
2. Protect completed stabilizer assembly with wood finish spray in the same manner as
completed in Step 5 of Wing Assembly.
Final Assembly
1. Install the stabilizer assembly. Lightly sand the last two inches of the carbon fiber pop-up
tail where it will interface with stabilizer assembly. With the fuselage sides held
perpendicular to your work surface and the stabilizer assembly flat upon the same
surface. Slide the stabilizer under carbon boom using the etch marks in the top of the
stabilizer assembly to align boom on appropriate side of stabilizer. The boom should
contact both the horizontal and vertical components of the stabilizer assembly and stops
flush at the trailing edge of the horizontal stabilizer. Important! Place a scrap piece of
1/8” balsa under the left tip of the horizontal stabilizer to provide initial stabilizer tilt.
Secure stabilizer to boom using thin CA glue. Lefties! place scrap 1/8” balsa under right
tip of stabilizer.

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© 2007 Stevens AeroModel. All Rights Reserved.
2. Install main wing to fuselage. With wing inverted lightly sand a flat to underside if center
wing joint. Align wing with top trailing edge of fuselage assembly. Align center joint of
wing assembly with center line of fuselage. Slide the 3/16” balsa wing jigs up from
bottom of fuselage to assist with holding the wing square while you tack glue the wing to
hold position. With the wing tack glued in place you will be able to adjust/align how it sits
atop the fuselage. Verify that the wing has been installed square relative to the fuselage.
Note the slight tilt to the stabilizer assembly in the drawing below as produced in step 1
(as viewed from rear of model). Once satisfied with installation apply liberal amounts of
thin CA glue to adjoining surfaces of wing and fuselage. Allow glue to cure then re-apply.
1/8 in.
3. Finger rest installation. Locate the 1/8” balsa triangular finger rest slightly round the
longest edge of the finger rest as illustrated below. Invert your glider and test-fit the
finger rest to the underside of the right wing panel. Lightly sand the inside edge of the
finger rest to allow it to seat flush against the fuselage side. Once satisfied with the fit
install the finger rest spanning the fuselage side and flush with the wing trailing edge.
Glue. Once the glue has cured, curl a length of fine sand paper around your finger and
sand a scallop in the trailing edge of the wing to match flush with the scallop cut in the
finger rest. Lefties! Install your finger rest on to the Left wing panel.

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© 2007 Stevens AeroModel. All Rights Reserved.
4. Wash-in wedge. Locate the 1/8” balsa “wedge” at this point it looks more like a block
than a wedge (first photo). Using a sanding block, taper the wedge evenly along the
length of the wedge (second photo). Install this wedge with the thickest point flush with
trailing edge of Left wing panel just outside of the first dihedral break (third photo).
Lefties! You will install wash-in wedge to Right wing panel.
5. Pop-Up spring forward lug assembly. From the remaining t-pin stock bend another “S”
hook just as you did in step 13 of the fuselage assembly. Measure 3/4” from wing trailing
edge and install this hook along center joint as illustrated. When inserting the hook drive
the straight pin portion of the hook at a 45 degree angle into the body of the wing and
fuselage. Glue.

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© 2007 Stevens AeroModel. All Rights Reserved.
6. Trailing edge DT string reinforcement. Locate the 1 in. length of .8mm dia. carbon rod.
Using a sharp razor blade or a small piece of sand paper, trim or sand a recess in the
wing trailing edge opposite the finger rest large enough to seat this length of carbon rod
flush to the wing trailing edge as illustrated. Glue with thin CA glue.
7. Put the “pop” in pop-up. Select two small rubber bands from the included rubber band
assortment and stretch over Pop-Up spring lugs as illustrated below.
8. Install DT string. Begin by making a large loop in the end of the provided abrasion
resistant string. Next, take your loop an tie an overhand knot. Work the knot down to
allow for a loop of about ¾” secure the knot with a drop of thin CA glue and remove the
short length of remnant thread.

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© 2007 Stevens AeroModel. All Rights Reserved.
9. Temporarily tape the Pop-Up boom within the fuselage as illustrated. Place a pin in the
top of the wing at the marked “high point” and place the looped end of the DT string over
the pin as illustrated.
10. Lefties! The following steps refer to building a right-handed glider reverse the sides
described in the instructions to complete your glider. Remember, the DT line will always
tie off on the opposite side of the timer.
Wrap the string over the carbon reinforced trailing edge of wing, underneath, and forward
to pass through the eye of the Left side DT string guide (first photo). Next, wrap the
string over the forward portion of the Pop-Up boom and up the opposite fuselage to pass
through the Right side DT string guide (second and third photo). With the DT string still
looped around the pin at top of wing remove any slack in the string and loop multiple
times through eye of Right side DT string guide (fourth photo).

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© 2007 Stevens AeroModel. All Rights Reserved.
11. Tie a simple overhand knot to retain string at Right side DT guide. Cut excess string and
secure knot with a drop of thin CA glue.
12. Select one of the longer rubber bands from your assortment and place thread through the
loop in the end of you DT string. Loop one side of the rubber band back through itself to
secure to the end of the DT string. Rotate the pin on the viscous timer to the ten-o-clock
position and loop rubber band over pin. You’ll notice immediately that the viscous timer
begins to rotate clockwise in response to the load placed on the pin. When the timer
reaches the two-o-clock position it will release the rubber band.
13. Balance model. Two tiny laser cut holes have been cut central to wing panel 1
approximately 1-3/4” aft of wing leading edge at root. These holes mark your CG
location. Balance the model, so that the fuselage hangs level with the horizon when
suspended from this point, by filling ballast pocket at nose of glider with clay ballast.
Alternatively, lead shot may be mixed with clay to reduce the bulk of ballast used.
Optional, cover the ballast pocket with 1/32” plywood plug to create a streamlined
14. You may now remove the tape from step 9 that prevented the operation of the pop-up
fuselage and proceed to the Flight Trim Guide for trimming and operation instructions.

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© 2007 Stevens AeroModel. All Rights Reserved.