Stevens Aero Model PuddleBug 2.4 User manual

PuddleBug
Micro RC Model for Spektrum / ParkZone 2.4 systems
Length 10.5 inches | Span 17.75 inches | Wing Area 71 inches2| Flying Weight 1.1 oz.
Version 01/06/2010
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 1 of 13
2.4

Product Support
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 2 of 13
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
Laser cut wood (6 Sheets - See inventory on following pages)
Illustrated instruction manual - Available for Download ONLY
Computer drawn 11x17 plan set (2 Pages)
Taped to Back of Wood Brick
2 - 12 in. Length of 0.015 in. dia. wire
2 - 12 in. Length of 0.025 in. dia. wire
Hardware Bag (4 x 6 in.)
1 - 1/64 in. Plywood Grill (F10)
1 - 1/32 in. Plywood Motor Mount Deck (F12)
1 - 1-1/2 in. Length of 1/16 in. Heat Shrink Tubing
1 - 3 in. Length of 1/16 in. Aluminum Tubing
1 - #2 Trexler Balloon Wheel
Required Electronics (Available at StevensAero.com)
Spektrum compatible radio with servo reversing. We suggest the DX5e.
ParkZone* [PKZ3351] or Spektrum [AR6400] Ultra Micro Receiver/ESC/Servo System.
ParkZone Motor and Gearbox [PKZ3624] (Same motor as used in the Sukhoi and UM P-51)
ParkZone UM P-51 Propeller [PKZ3601] or E-Flite* 4-Site Propeller [EFL9051]
ParkZone [PKZ1035] or E-Flite [EFLB1201S] 110-120mAh 3.7V LiPo Battery
*Recommended
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 3 of 13
Required Building Supplies and Tools
1/2 oz. Medium CA Glue
1/2 oz. Thin CA Glue
CA glue accelerator (kicker)
Hobby Knife with ample supply of #11 blades
Sanding block with 400 and 600 grit paper
Covering Iron and Heat Gun
Small Needle Nose Pliers
Small Round “Rat-Tail” file.
1 in. x 2 in. length sticky back velcro
3/4 in. wide clear tape
1 Roll AeroLITE (solite)
Suggested Building Supplies
CA glue de-bonder
Long sanding bar
Low Tack Painters Masking Tape
Dubro Servo Tape [DUB-634]

General Assembly Instructions
Thank you, for purchasing this Stevens AeroModel PuddleBug™. An indoor micro RC model developed
for the popular Spektrum and ParkZone 2.4ghz micro receiver/esc/servo “brick” or “puck” systems. 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, 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. At any time should you 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.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 5 of 13

Wing Construction
Locate and join together over plan sheet parts
W1a and W1b to create the wing center
section sheeting.
Next, locate parts W2a and W2b. Join
together so that the etching on the frame is
on the same side. Build a right and left frame.
Begin building by laying the wing frame flat
atop your work table (text/etch marks up).
The ribs will be inverted when assembled to
the wing frame. Locate and install R2 to the
wing panel by aligning a front most tab and
notch. Glue.
Install ribs R3, R4, and R5 aligning first at
notch point and etch lines in leading edge of
wing frame. Glue ribs at leading edge.
Lay the wing down atop a flat surface with the
portion of the wing forward of the spar taped
flat against the surface. Wrap the wing panel
aft into position at trailing edge tab and notch
points. Align ribs to etch lines and glue.
Install S2 and S3 spars to right and left wing
panels within notches at wing frame and ribs
R2, R3, R4, and R5.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 6 of 13

Wing Construction Continued
Build the wing center section from W1
sheeting (previous assembly of W1a/W1b),
ribs R1, and ply spar S1. Key ribs R1 to the
spar S1 using the notches in the spar as a
reference for spacing. Glue.
Next, aligning with the tabs on ribs R1, wrap
center section sheeting W1 assembly over R1
ribs and glue in place.
Edge of W1 follows centerline of ribs R1.
Join completed right and left wing panel to
completed wing center section.
Fit the spar S1 to the notch in the bottom of
ribs R2 and R3.
Wing root edge should align with tabs in ribs
R2 and fit flush with edge of center section
sheeting. Once satisfied with alignment, glue.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 7 of 13

Wing Construction Continued.
Check wing for twist. Sight along the bottom
portion of ribs forward of the spar S1.
Straight wings will have each rib bottom
parallel to the next. Warped wings will show
deviation from rib to rib. To correct a warped
wing: mist wing panel with glass cleaner, then
pin to a flat building surface. Once
completely dry, the wing will assume the
shape of the surface it has been pinned to.
Final sand wing. Then using a clear lacquer
or polyurethane based spray, apply a light
coat to seal the wood. We suggest “Deft”
brand “Clear Wood Finish”.
Use the covering guide on plan sheet 1 of 2
to cut the covering for your wing panels and
apply according to the directions provided by
your covering film manufacture. We suggest
AeroLITE covering film, available at
StevensAero.com
Cover only the top surface of the wing.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 8 of 13

Fuselage Construction
Build the central crutch. Locate parts F1, F2,
and F3 then dry fit (use no glue) these
components together in the order illustrated
on the plan sheet.
Locate central crutch assembly to the notches
in the right fuselage side then glue.
Fit tab of F7 to notch in F3, align holes for
axle at fuselage side, then bond to inside
surface of fuselage as illustrate on plan.
Bond one F6 part to inside surface of right
fuselage side as illustrated on plan.
Key former F4 to tabs provided in right
fuselage side.
Fit left fuselage side to assembly. Square
structure on work table then glue at all
contact points.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 9 of 13

Fuselage Construction
Repeat process for installing F7 and F6 within
fuselage assembly, bond within fuselage
against left fuselage side.
Install F5 to the top of the fuselage assembly
then glue.
Bond ply grill F10 to front of parts F7, flush
with fuselage sides.
Bond ply fender F11 to F10 above wheel
opening as indicated on plan sheet.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 10 of 13

Fuselage Construction
Using a sharp #11 blade, complete cutting of
notch that runs through former F5. This will
allow passage of strut wire through fuselage.
Now, harden the balsa wood at slot on
fuselage sides where strut wire will pass
through.
Bond ply motor mount doubler F12 on top of
F3 between parts F6.
Install F9. Find edge opposite “U” shape cut
in F9 and position this edge flat against
leading edge of F5 atop F6. First, glue F9
where it contacts F5.
Then, wrap/bond F9 down along top edge o
F6 spanning fuselage sides.
Locate two cross-grained parts F8 (F8a and
F8b) to inside of parts F7 behind grill - see
“Wheel / Axle Detail”. Use the 1/16 in.
aluminum tube axle as alignment guide. Tack
glue parts F8 with med. CA glue. DO NOT
GLUE AXLE IN PLACE. Remove axle tube
and permanently glue F8 with thin CA.
Using a sharp #11 blade shape inside surface
of F8 to match radius/relief in grill for tire.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 11 of 13

Final Assembly
Follow plan on sheet 1 and assemble
Horizontal Stabilizer as illustrated.
Using a clear lacquer or polyurethane based
spray, apply a thin coat to seal the fuselage
and tail surfaces. We suggest “Deft” brand
“Clear Wood Finish”
Use the covering guide on the plan sheet to
cut the covering for your Horizontal Stabilizer
and apply according to the directions
provided by your covering film maker. We
suggest AeroLITE covering film, available at
StevensAero.com
Completed Horizontal Stabilizer assembly
keys to tabs atop aft end of fuselage
assembly. Square horizontal Stab to fuselage
sides, and glue.
Locate parts V3 Strakes to underside of H4 in
Horizontal Stabilizer and glue.
Trim mounting post from motor gear box
[PKZ3624] prior to installation.
Now, install gearbox through opening in F9
and glue to ply motor mount doubler. Ensure
that there is no side thrust before gluing with
medium CA glue.
Sand bevel, then hinge elevator and rudder to
horizontal and vertical stabilizers with clear
tape using the reference on plan sheet 2 of 2
as a guide.
Install Micro receiver brick on bottom of F4
with double sided servo tape [DUB634]
Glue rudder control horn to left side of rudder.
Glue elevator control horn to lower right side
of elevator.
Follow the detail on plan sheet 2 of 2 for
creating and installing servo linkage.
Bend 0.015 in. dia. wire strut using template
on plan sheet 2 of 2 as a guide.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 12 of 13

Final Assembly Continued
Fit and glue one S2 ply tab to inside of one rib
R1 straddling ply spar.
Insert strut wire through tab.
Slide remaining S2 tab onto wire and glue tab
inside opposite rib R1.
Using a Trexler inflating pump [TRX-HP] or
SIG syringe [SIGSH627], carefully fill you tire
with air. Do not inflate the tire using your
mouth. Moisture from your breath will
permanently damage the inflation tube. Do
not overfill tire as this will bulge or otherwise
deform the tire.
Twist inflation tube three times.
Wrap inflation tube around hub once then
tuck remaining tube neatly between tire and
hub.
Mount tire in base of fuselage with 1/16 in.
dia. aluminum tube axle. DO NOT GLUE
AXLE IN PLACE as this will allow removal of
Trexler tire for inflation/deflation before and
after flying sessions.
Extend the battery lead from your receiver if
necessary, and route through opening in F5
and under slot in rib R1 of right wing.
Mount wing by sliding tabs S2 into slots in F5,
guiding strut wire through slot in fuselage
sides.
Slide end of struts into ends of axle tube to
secure wing.
Stack the round balsa parts “a” - “j” atop one
another and glue to form fax glow head.
Paint black and fit/glue to the opening in F9.
Balance model at ply wing spar S1. Mount
the battery under the right wing outboard of
rib R1 with Velcro. Locate the battery fore/aft
to achieve proper balance.
PuddleBug © 2010 Stevens AeroModel all rights reserved. Page 13 of 13