Stevens Aero Model SkyBoy 600 User manual

SkyBoy (600)
By Stevens AeroModel
Length 36 inches | Span 48 inches | Wing Area 640 inches2| Flying Weight 36 oz.
Version 12/03/2010
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 1 of 55

Product Support
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 2 of 55
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 (29 Sheets - See inventory on following pages)
☐Illustrated instruction manual
☐1 - Pre-Bent landing gear (1/8 in. dia. wire)
☐1 - Laser cut wind screen
☐1 - Laser cut color profiles for pilot figure
Strip Wood
☐2 - 3/8 in. square x 36 in. balsa stock (Leading Edge)
☐3 - 1/4 in. square x 36 in. balsa stock (Main Spar Cap Strips)
☐4 - 3/16 in. square x 36 in. balsa stock (Turbulator Spars, Fuselage and Aileron Stiffeners)
☐2 - 1/8 in x 3/16 in. x 36 in. balsa stock (Sub Spar Stiffener)
Long Hardware
☐2 - 18 in. x 1/32 in. inside dia. plastic pushrod housing [SUL-S98117]
☐2 - 18 in. x .032 wire [SUL-S97253]
☐1 - 18 in. x .045 wire [SUL-S97254]
☐2 - 12 in. x 1/2 in. paper tube
5 x 8 Hardware Bag
☐6 - #32 rubber bands
☐4 - Razor Control Horns [DUB936]
☐3 - 3/16 in. x 4.5 in. hardwood dowels
☐2 - Wing Tip Skids [DUB990]
☐1 - Pkg Large Rubber Bands [HBZ7127]
☐1 - 3/4 in. tailwheel
☐1 - Pkg 1/8 in. wheel collars [DUB139]
☐1 - 1/32 in. laser cut ply grill (Part F16)
☐1 - 1/16 in. laser cut ply wing trailing edge reinforcement (Part W9)
☐1 - 3/16 in. laser cut basswood elevator joiner (Part E6)
☐1 - Hardwood landing gear block cut to 2-5/8 in. length [SIGSH655]
3 x 2 Hardware Bag
☐4 - 4-40 Blind Nuts
☐4 - 4-40 x 1/2 in. Pan Head Machine Screws
☐4 - 0 x 3/16 in. Screws
☐4 - Micro E/Z Connectors [DUB845 2 pkgs]
☐4 - CA Hinge [SIGSH710M]
☐4 - 3/16 in. dia. x 1/16 thick Neo. Magnets
☐2 - Micro E/Z Links [26310]
☐2 - Micro II E/Z Links [27805]
☐1 - 1 in. length Silicone Tube
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 3 of 55

Required Electronics (Available at StevensAero.com)
☐4 Channel radio and micro receiver. We suggest the Spektrum DX6i and AR500 receiver.
☐2 - HS-82MG servos
☐2 - HS-65HB servos
☐2 - 12” Servo Extensions
☐SA Sport BL.10 Motor [SUPA2418-8]
For 11.1V power system use:
☐Thunderbird 36 36Amp ESC [CSETB36]
☐11x5.5E Propeller [APC12060E]
☐Hyperion G3 7.4V 2100mAh 3 cell LiPo Battery [HP-LG325-2100-3S]
For 7.4V power system use:
☐SA Sport - 30Amp ESC [SUP30AESC]
☐12x6SF Propeller [APC12060SF]
☐Hyperion G3 7.4V 2100mAh 2 cell LiPo Battery [HP-LG325-2100-2S]
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 4 of 55
Required Building Supplies and Tools
☐Pair 4-1/2 in. Big Lite Wheels [DAV5740]
☐1 oz. Medium CA Glue
☐1/2 oz. Thick CA Glue
☐1 oz. Thin CA Glue
☐CA glue accelerator (kicker)
☐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
☐1 in. x 12 in. length sticky back velcro
☐3/4 in. wide clear tape
☐2 Roll AeroLITE (solite)
☐1 Roll AeroTRIM (solartrim)
Suggested Building Supplies
☐CA glue de-bonder
☐Long sanding bar
☐Razor Plane
☐Low Tack Painters Masking Tape

Laser Cut Parts Inventory
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 5 of 55

Laser Cut Parts Inventory
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 6 of 55

Laser Cut Parts Inventory
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 7 of 55

Laser Cut Parts Inventory
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 8 of 55

Laser Cut Parts Inventory
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 9 of 55

General Assembly Instructions
Thank you, for purchasing this Stevens AeroModel SkyBoy (600)™. The SkyBoy (600)™ was inspired
by our good friend Kris Cartwright who brought in a sketch of a low wing companion plane for our
SkyBuggy. With an obvious tip of the hat to Andy Clancy and his “Bee” series of models, along with it’s
nostalgic lines, the SkyBoy (600)™ was just too good not to share with the R/C modeling community.
SkyBoy (600)™ is a gentle flyer suitable for the intermediate pilot, and we’re sure you’ll have many hours
of pleasure flying at the local park or school yard.
SkyBoy (600)™ 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.
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 5 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 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.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 10 of 55

Tail Feathers
☐Horizontal Stabilizer: Begin by fitting HS1a
and HS1b together to form HS1. Bond with
thin CA
☐Bond part HS2 to HS1 assembly
☐Bond parts HS3 to each end of HS2
☐Bond HS4 to HS1 assembly and parts HS3 to
complete outer frame.
☐Bond cross piece HS5 and “B” diagonals to
each side to complete Horizontal Stabilizer.
☐☐ Elevator: Build one half at a time. Start
by bonding E1 to E2.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 11 of 55
HS1a
HS1b
HS4
HS2
HS3
HS3
HS2
HS1
HS3
HS3
HS5
E1
E2
HS1
“B” Diagonals

Tail Feathers Cont.
☐☐ Bond E3 to E2.
☐☐ Bond E4 to E3 and E1 to complete outer
frame.
☐☐ Bond E5 and “C” diagonals to complete
Elevator half. Repeat previous ☐☐
steps to build second half.
☐Using a straight edge as a guide, join
Elevator halves with hardwood part E6. Bond
with medium CA.
☐Vertical Stabilizer: Bond parts V1, V2, and
V3 together to form Vertical Stabilizer frame.
☐Rudder: Using a short length of .045 wire,
scrape out the etched areas on parts R1 and
R2 to create a recess for the tail wheel wire.
The recess should be just deep enough for
the .045 in wire to seat snuggly.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 12 of 55
E2
E3
E1
E3
E4
E5
E6
V1 V2
V3
R2
Straight Edge
“C” Diagonals

Tail Feathers Cont.
☐Bond parts R1 and R2 together with thin CA.
☐Bond R3 to R2.
☐Bond R4 to R3.
☐Finally bond R5 to R4 and R1 to form Rudder
outer frame.
☐Bond part R6 and “A” diagonals to complete
Rudder Frame.
☐Tailwheel: Cut a length of .045 in. wire to
5-1/2 in. long.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 13 of 55
R1
R2
R2 R3
R3
R4
R5
R1 R4
R6
“A” Diagonals
5-1/2 in. Long

Tail Feathers Cont.
☐Make a 90 degree bend 1-1/8 in from one
end.
☐7/8 in. from the first bend, make a 45 degree
bend.
☐Two inches from the second bend, make
another 45 degree bend, 90 degrees from the
plane of the first two bends.
☐Make another 45 degree bend 1/4 in. from the
last bend.
☐Make a 90 degree bend 1/2 in. from the last
bend.
☐Trim any excess wire 1/2 in from the last
bend.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 14 of 55
A
1-1/8 in.
AB
7/8 in.
A
BC
2.0 in.
D
C
1/4 in.
CD E
1/2 in.
E
1/2 in.
D
C

Fuselage Construction
☐Mount the provided 3/4 in. tailwheel.
☐Bend end of wire over to retain wheel.
☐Fit tailwheel wire to recess in parts R1 and R2
of Rudder. Secured with medium CA.
☐Using thick CA, bond R7 to base of rudder,
trapping wire. Ensure holes for rudder horn
line up and are not fouled with glue.
☐Bond remaining R7 to the other side of the
Rudder with thick CA.
☐Bevel leading edge of rudder and elevator at
a 45 degree angle.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 15 of 55
45 deg.
R7
R2
R1
R7
45 deg.

Fuselage Construction
☐Crutch Assembly: Fit F1 crutch to F2
former. Tack glue with a small amount of
medium CA.
☐Bond F3b to bottom of F3 with thin CA.
☐Slide F1 through lower part of F3, up to the
notches behind F2.
Carefully twist F3 into place.
Tabs on F3 will rest on top of F1 crutch. DO
NOT GLUE.
☐Fit F4 to slots in F1 just behind F3. Prongs
on F4 point in the same direction as the tops
of F2/F3. DO NOT GLUE.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 16 of 55
F1
F2
F3
F3b
F3
F2
F1
F2
F3
F1
F1
F4
Top
Top
Up
Top Tab
Top View
Top View

Fuselage Cont.
☐Bond F5b to bottom of F5 with thin CA.
☐Slide F1 through F5 and carefully twist into
place.
Ensure tabs seat firmly on F1 - one on the
top, the other below. DO NOT GLUE.
☐Bond F6b to bottom of F6 with thin CA.
☐Fit F6 to taps at the end of F1. DO NOT
GLUE.
☐The completed fuselage crutch assembly
should appear as below. Ensure that all
formers are positioned correctly, with their
tops up then tack glue with medium CA.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 17 of 55
F5
F5b
F6
F6b
F5
F1
F6
Top
Top View
Tab
Tab
Top
F6
F2 F3 F4
F5

Fuselage Cont.
☐Fuselage Doubler: Build right side first.
With etching facing up, fit FDa, FDb (RIGHT),
and FDc together and bond with thin CA.
☐On a smooth, flat surface, fit FDd (RIGHT) to
previous assembly. Ensure that etching on
all parts face up.
☐Ensure pieces are flush with table top.
FDa,b,c assembly will stand proud of FDd by
3/32 in. bond with thin CA.
☐With etching on fuselage doubler facing up, fit
fuselage crutch to doubler.
☐Ensure tabs on crutch extend through forward
part of doubler 3/32 in. as shown. Tack glue
crutch to doubler with medium CA.
☐Cut longeron from 18 in. length of 3/16 in.
square balsa to and fit to slots in formers and
fuselage doubler. Tack glue at formers F2
and F3 only.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 18 of 55
Right Side
FDa FDb FDc
FDd
FDa,b,c
Glue Here
Longeron
F2
F3
Top
Bottom
(RIGHT)
3/32 in. Proud

Fuselage Cont.
☐Longeron will touch the top of F4 - DO NOT
GLUE.
☐Allow longeron to extend past F6 a little. This
will be trimmed later. DO NOT GLUE.
☐Fuselage Side: Fit and bond parts FSa and
FSb together with thin CA.
☐☐ Fit and bond FSc to FSb.
☐☐ Fit and bond FSd to FSc and FSb.
☐☐ Fit diagonal braces in slots in fuselage
side.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 19 of 55
F4
Longeron
F6
Longeron
FSa
FSb
FSa
FSb
FSc
FSc
FSb
FSd
Diagonals

Fuselage Cont.
☐☐ Ensure that numbers on the ends of the
diagonals match the numbers on the
slots. Bond with thin CA.
☐Test fit completed fuselage side to crutch/
doubler assembly. Ensure, and familiarize
yourself with, the fit of all parts.
☐Remove fuselage side and coat doubler with
thick CA then...
...immediately re-fit fuselage side pressing
doubler/side together on a flat surface.
☐Hold assembly on a flat surface and bond all
mating surfaces with medium CA.
☐Motor Mount: With the etched (back) side
facing up, drive the four blind-nuts in the
circled holes of F7 with a hammer.
SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 20 of 55
3
3 3
BACKF7
F2