Stevens Aero Model SCRAM! User manual

SCRAM!
1/2A Electric Control Line Combat by Stevens AeroModel
Length 12 inches | Span 18 inches | Wing Area 100 inches2| Flying Weight 4 - 4.5 oz.
Version 12/24/2009
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 1 of 25

Product Support
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 2 of 25
WARNING! DANGER!
DO NOT FLY MODELS NEAR ELECTRIC POWER LINES. INSTANT DEATH CAN RESULT FROM
CONTACT WITH, OR FLYING TOO CLOSE TO, ELECTRIC POWER LINES.
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.

Project Checklist
Kit Contents
Laser cut wood (8 Sheets - See inventory on following pages)
Illustrated instruction manual
1 - 1/32 in. x 12 in. music wire (taped to back of wood brick)
1 - 3/16 in. square x 18 in. length hardwood stock (Leading Edge)
1 - 3/32 in. x 3/16 in. x 12-3/4 in. Basswood Stock
Large Hardware Bag (4 x 6 in.)
1 - 1/2 in. x 5 in. strip 2-sided velcro (Battery Safety Strap)
1 - Nylon Bell Crank
1 - 2 in. x 1/32 I.D. Nylon Tube (Lead-out Wire Guides)
1 - 36 in. length 0.012 Stainless Wire
1 - “W8” Laser Cut Basswood Part (3/32 in. x 3/16 in. x 3-1/4 in.)
Small Hardware Bag (2 x 3 in.)
1 - US Nickle (Cheaper than Lead thanks to the Fed!)
1 - 0.060 in. OD x 2 in. Length Carbon Rod
1 - 4-40 Blind Nut
1 - 4-40 x 3/8 in. Pan Head Machine Screw
1 - Du-Bro RC 4-40 Hex Nut [DUB561]
1 - Du-Bro RC Micro Razor Control Horn [DUB936]
1 - Du-Bro RC Micro EZ-Link [DUB849]
1 - Du-Bro RC Mini E/Z Connector [DUB845]
1 - 3/32 in. OD x 1-5/16 in. Length Aluminum Tube
2 - Du-Bro RC #4 Flat Washers [DUB323]
4 - 1/16 in. OD x 1/4 in. Length Aluminum Crimp Tube
Required Electronics & Equipment (Available at StevensAero.com)
1 - StevensAero/Suppo Park 300 Brushless Outrunner Motor [SUPA2204-19]
1 - StevensAero/Suppo 10A Brushless ESC [SUP10AESC]
1 - E-flite Control Line Motor Timer [EFLA172]
1 - ThunderPower RC Pro-Lite V2 350mAh 11.1V LiPo Battery [THP3503SJPL2]
1 - GWS 6x3 HD Propellor [GW/EP6030]
1 - SIG 1/2A Control Handle, inc. Dacron Line and Connectors [SIGSH544]
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 3 of 25
Required Building Supplies and Tools
1/2 oz. Medium CA Glue [PAAPT09]
1/2 oz. Thin CA Glue [PAAPT03]
1/2 oz. Thick CA Glue [PAAPT20]
CA glue accelerator [PAAPT15]
Balsa filler [HCAR3401]
Hobby Knife with ample supply of #11 blades
Small Phillips Screwdriver
Small Hammer
Sanding block with 400 and 600 grit paper
Heat Gun and Covering Iron
Small Needle Nose Pliers
Small Round Nose Jewelers Pliers
X-ACTO Pin Vise Set [XAC7155]
ZONA 4 in 1 Saw Set [ZON35251]
Scissors
Wire Cutters [HDCUT093]
Z-71 Thread Locker [PAAPT71]
1 in. x 4 in. length sticky back velcro
1 Roll StevensAero AeroLITE
Suggested Building Supplies
CA glue de-bonder [PAAPT16]
Long sanding bar
Razor Plane
Low Tack Painters Masking Tape
Design Master Aerosol Paint

General Assembly Instructions
Thank you, for purchasing this Stevens AeroModel SCRAM!, 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, 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. As this kit is recommended for the novice 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.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 5 of 25

Wing Construction
Locate the 4/40 blind nut within the hole in
W6L. Ensure that etching on W6L faces up.
With a hammer, seat blind nut firmly in W6L.
Secure with medium CA at edge of nut flange.
Bond together both ribs R1 with medium CA.
Align carefully, match at notches and profile.
Fit and bond trailing edge parts W3a and
W3b.
Dry fit R1 assembly to trailing edge. DO NOT
BOND AT THIS TIME.
Fit gussets W4 to trailing edge and R1
assembly. Align and bond.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 6 of 25

Wing Construction Cont.
Slide dovetailed end of W6L through the left
side of the slot in R1 assembly. Ensure that
etching on W6L faces up, and blind nut is on
top as shown. DO NOT BOND.
Note that dovetail will protrude through R1.
Dry fit left R2 to trailing edge and W6L. DO
NOT BOND.
Fit W6R to W6L. Fit left R2 to W6R and
trailing edge. Be sure entire assembly is flat
and square. Tack glue all joints with thin CA.
Note that W6R will “dovetail” into W6L as
illustrated below.
Fit ribs R3 and R4 to trailing edge. Tack with
thin CA.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 7 of 25

Wing Construction Cont.
Dry fit upper laser cut balsa front spar part
“W1” to upper notches in ribs R1-R4.
Dry fit 3/32 in. x 3/16 in. basswood stock to
notches below W1 front spar spanning ribs
R1-R4 to form lower front spar.
Insert rear spars W5 through all ribs. Ensure
that structure is flat and square, and bond all
joints with CA.
Mark center of 1/4 in. square hardwood
leading edge stock. Align mark with center of
wing at R1, then bond leading edge stock
within notch at leading edge of all ribs.
Build left wing tip. Align and bond TL2a,
TL2b, and TL2c atop part TL1 with thick CA.
Align and bond TL3 ton top of TL2 parts with
thick CA. Ensure that lead-out slots are not
blocked with CA.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 8 of 25

Wing Construction Cont.
 Dry fit left wing tip assembly to left side of
wing at trailing edge.
 Carefully nest leading edge stock within
slot at front of wing tip.
 With wing tip fit flush to rib R4, leading
edge, and trailing edge, bond with
medium CA.
Build right wing tip. Align and bond parts TR2
atop TR1 and TR3 atop TR2 using thick CA.
Repeat prior steps to bond right wing tip
to right side of wing assembly.
Bond a nickel (5 tip weight) within pocket
created by TR2 at right wing tip. (Inflation...
Prior to going off the gold standard, a nickel
would have purchased this kit. Today, the
nickle is more affordable to use than lead!)
Use a razor saw to trim the excess leading
edge stock at left and right wing tips.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 9 of 25

Wing Construction Cont.
Bond with thick CA, R2a cross grain doubler
to outside edge of right rib R2 (this is the rib
adjacent to battery tray W6R).
 The inside surface of W2, leading edge
sheeting, has been laser scored and
center marked as illustrated below. Align
rectangle etched to W2 sheeting with
center rib R1 to center leading edge
sheeting with wing assembly. The closer
spaced score lines on W2 indicate the
side of sheeting that should be installed
closest to the hardwood leading edge
stock.
 Bond W2 leading edge sheeting first, only
to top of the 1/4 in. leading edge stock.
 Starting in the center of the wing,
carefully bend down W2 sheeting to
follow contour of ribs and bond to the
upper spar W1. Work from the center
out, one rib bay at at time, alternating
from right to left side of wing.
 Bend end of W2 down to sit flush with
wing tip and bond. W2 should stop short
of wing tip profile as shown.
 Repeat steps above to install the
lower leading edge sheeting W2.
Fit W4 cap strip to top of rib R1 assembly.
Bond against leading edge sheeting first.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 10 of 25

Wing Construction Cont.
Press W4 flat against trailing edge and bond
with CA. Bond the rest of W4 to R1 assembly.
Carefully sand W4 to a smooth taper into the
trailing edge. Tip: apply masking tape to
areas you wish to protect from the sanding
process.
Invert wing and remove stand off tabs. Note
there are two tabs on R1 assembly.
Bond W11 to bottom of rib R1 assembly. W11
should be centered on R1 and fit flush against
leading edge sheeting.
Bond basswood part W8 to bottom of lower
rear spar spanning ribs R2.
Fit and bond ply W7 pushrod exit centered to
R1 ribs as illustrated.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 11 of 25

Wing Construction Cont.
Use one of the ply motor mount parts to
reference the proper profile for the wing
leading edge.
With a razor plane and sanding block/bar
shape the basswood leading edge until the
proper airfoil contour is reached.
Round off wing tips and leading edge leaving
trailing edge of wing square. Gently sand the
rest of the wing smooth with 600 grit sand
paper.
The battery will be mounted within the wing.
Install 5 in. length of 1/2 in. wide velcro strap.
Velcro is installed through slots in W6R ply
support from top of wing.
Fasten strap to itself to keep it out of the way
while covering the wing. Strap can not be
installed after wing is covered.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 12 of 25

Wing Construction Cont.
Install E/Z Connector [DUB845], 3/8 in.
machine screw, washers and nut as shown...
...one washer on each side of the control
bellcrank. Do not tighten nut - it will snug
down on final installation.
Cut yellow nylon tube in half and slide into
lead-out slots of left wing tip. Bond with
medium CA. and trim tubes flush with tip.
First, cover left wing tip. Now, loop provided 3
ft. length of 0.012 in. stainless wire through
lead-out slots in wing tip and ribs R2-R4.
While leaving wires looped through wing,
attach lead out wires to belcrank using the
following ★method.
Install one aluminum crimp tube to wire then
thread wire through outside hole in bellcrank.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 13 of 25

Wing Construction Cont.
Loop wire back through aluminum crimp.
Make a second loop through aluminum crimp.
Tighten loop as illustrated. Using round nose
or fine needle nose pliers place two crimps in
tube and secure with a drop of medium CA
glue at each end of crimp.
Using wire cutters trim excess wire.
Revisit previous ★steps to complete loop
and crimp for opposite side of bellcrank.
Further secure crimps with a drop of CA glue.
Put a drop of thread locker on end of
machine screw and mount bellcrank
assembly to blind nut in W6L mount. Gently
snug down screw until bellcrank is free of
wobble but rotates smoothly.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 14 of 25

Wing Construction Cont.
To prevent lead-out wire from falling back into
the wing, place two loops of masking tape
around wires as illustrated. Now, cut lead-out
wire in half at looped end as illustrated.
Center bellcrank then follow previous ★
steps to finish outside lead-outs leaving at
least 2-3 in. of lead-out wire beyond wing tip.
With lead-outs complete, cover wing using
AeroLITE or AeroFILM.
Stabilizer Assembly
The vertical fin E1a and E1b have been deep
engraved to recess and locate ply parts E2.
Use a flat-head screw driver to lightly scrape
away residue from the engraving process.
Photo shows part with residue properly
removed.
Bond 1/32 in. ply part E2 within recessed
pockets to both E1a and E1b with thick CA.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 15 of 25
E2

Stabilizer Assembly Cont.
Align and bond E1a to E1b using thick CA.
Ply parts E2 should remain on the outside
surfaces of the completed assembly.
From provided length of 3/32 in. OD alum.
tube cut a 1/4 in. length.
Install cut length of tube centered to fin
assembly contained by the holes in E2.
Secure with thin CA glue.
Sand outside edges of vertical fin assembly.
DO NOT SAND inside the “V” of the fin.
Test fit the fin to the wing assembly centered
at the trailing edge of R1 as illustrated. DO
NOT GLUE
Lightly sand the edges of E3 elevator round in
preparation for covering. Do not sand away
the notch in the leading edge of the elevator.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 16 of 25
NOTCH

Motor Mount
Dry fit parts M1a to M3 as illustrated.
Dry fit M2a so that it seats flush to M1a and
M3. Tabs from M1a and M3 should extend
1/16 in. proud of the surface of M2a. Once
satisfied that the assembly is correct bond
with medium CA glue.
Using medium CA glue bond M2b atop M2a.
Bond balsa parts M1b to the outside surface
of M1a on both right and left sides of mount.
Sand balsa sides of mount round to follow
contour of M2a/b. DO NOT SAND within the
“U” of the mount.
Test fit mount to wing leading edge centered
at rib R1. DO NOT GLUE.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 17 of 25

Final Assembly
Cover or paint the completed vertical fin using
AeroLITE or AeroFILM.
Cover or paint the completed motor mount
using AeroLITE or AeroFILM. There’s no
need to cover/paint within the “U” of the motor
mount.
Cover or paint the horizontal stabilizer using
AeroLITE or AeroFILM. Remove covering
from notch at leading edge of stabilizer.
Verify that provided 0.060 in. carbon fiber rod
is cut to 2 in. length and fits within notch.
Slip 0.060 in. carbon fiber rod through bearing
in vertical fin. DO NOT GLUE
Temporarily retain horizontal fin to carbon rod
pivot rod using masking tape and tack glue
using medium CA. After glue cures, remove
tape and glue rod thoroughly to horizontal
stabilizer. ENSURE THAT NO GLUE
ENTERS ALUM. BEARING AT PIVOT.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 18 of 25

Final Assembly Cont.
After glue cures, apply 1 in. lengths of 3/4 in.
wide clear tape to left and right side of
horizontal stabilizer spanning pivot.
Open up pocket on underside of wing
exposing the battery mount and bell crank.
Then, using a fine tipped hot soldering iron,
open up the push-rod exit in wing on same
side as where bellcrank has been installed.
Mount vertical fin to wing, centered to and
parallel with, rib R1. Bond fin to wing with
medium CA glue. Before glue sets ensure
that horizontal stabilizer is square to wing. It
is not suggested to remove covering on wing
for install of fin.
Make a 1/8 in “L” bend at one end of the
provided length of 1/32 in. diameter wire. Cut
wire to a total length of 7-1/2 in. then insert
through push-rod slot in wing with “L” bend at
horizontal stabilizer.
On underside of wing install Du-Bro RC Micro
Razor Control Horn [DUB936] to same side
as push-rod. Bond control horn to stabilizer
with medium CA glue.
Glue posts to control horn backing plate on
opposite side of stabilizer then trim excess
length of posts from control horn assembly.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 19 of 25

Final Assembly Cont.
Retain push-rod to control horn using the Du-
Bro RC Micro EZ Link [DUB849]. Pass
opposite end of push-rod through Du-Bro Mini
EZ Connector [DUB845] previously installed
to bellcrank. Center horizontal fin, square
bellcrank, then snug/retain push-rod using set
screw in EZ Connector.
Connect push-rod to outside hole in control
horn to reduce sensitivity for beginner pilots.
Inside hole should be used for advanced
pilots wishing maximum maneuverability.
Glue motor mount to leading edge of wing
centered to rib R1. Mount should be glued at
six points (three right and three left) as
indicated by the using thick CA. Thicker
“legs” of motor mount should be oriented to
underside of wing as illustrated.
Note: Thrust line should be zero to wing with
no right or down thrust. Limit your glue usage
to small amounts in the areas specified - the
premise is that; in the event of a crash this
mount will pop free from the relatively slick
covering thus limiting crash damage to wing.
Use the hardware provided with your
StevensAero/Suppo 2204-19 motor and
mount to model, routing the motor wires
through the hole in the motor mount.
Connect StevensAero/Suppo 10A ESC
(Electronic Speed Control) to motor then use
sticky back velcro (not provided) to retain
ESC between formers of motor mount on
lower side of wing.
Using sticky back velcro (not provided) retain
lipo battery to battery mount and secure with
velcro strap.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 20 of 25
Thicker “Legs”

Final Assembly Cont.
Mount E-Flite timer [EFLA172] as illustrated
to top of wing using sticky backed velcro (not
provided).
Mount propeller to motor using hardware
provided with your motor. We suggest using
a prop-saver style mounting.
Your SCRAM! is ready to fly! Tie your combat
ribbon off to the control horn and go fly!
Cautions
When starting the motor, securely grasp
airframe by motor mount at the leading edge
of the wing. Keep hands and fingers clear
of the prop arc at all times!
Support Crew Instruction: Ensure that the
pilot is holding controls at neutral. Grasp
airframe by wing tips, palms up, between your
thumb and fingers. Elevate nose of model at
15-20 degrees. Start motor and allow to
motor to come to full throttle. Gently toss
model forward then immediately clear
yourself outside of the flight circle.
Danger Caution! if pilot is holding “up”
control input the model could immediately
loop on take off and strike you from
behind. Quickly clear the flight circle after
launch.
SCRAM! © 2009 Stevens AeroModel all rights reserved. Page 21 of 25