THUNDER TIGER Cloud Dancer 40 ARF TTR4542 User manual

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ThunderTiger Cloud Dancer 40ARF (TTR4542)
Distributed in NorthAmerica byAce Hobby Distributors,Inc.• 116W 19th ST,Higginsville,MO 64037
660-584-7121 • www.acehobby.com • [e-mail]
CloudDancer40ARF
Assembly Manual
Wingspan: 60”
Length: 46.75”
Wing area: 625 in2
Weight: 4lbs
Engine: .40-.46 2 Cycle
.40-.53 4 Cycle
Radio: 4 Channel
Specifications:
Warranty
This kit is guaranteed to be free from defects in material and workmanship at the date of purchase.
It does not cover any damage caused by use or modification. The warranty does not extend beyond the
product itself and is limited only to the original cost of the kit. By the act of building this user-assembled
kit,the user accepts all resulting liability for damage caused by the final product. If the buyer is not
prepared to accept this liability,it can be returned new and unused to the place of purchase for a refund.
21041/JE6439
Notice: Adult Supervision Required
This is not a toy. Assembly and flying of this product requires adult supervision.
Read through this book completely and become familiar with the assembly and flight of this airplane.
Inspect all parts for completeness and damage. If you encounter any problems,call 660-584-6724 for help.

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INTRODUCTION
All of us atThunderTiger want to thank you for choosing one of the finest 40 sized sport planes available,the Cloud Dancer 40.Designed by the
late Fred Reese, this airplane offers a unique appearance and sprightly, yet predictable performance. This model features state-of-the-art
engineering that provides quick and easy assembly of a strong,yet lightweight airplane that will give you an enjoyable and thrilling experience.
To gain the most from this airplane kit, it is important that you read the instructions thoroughly and then follow them exactly. We strongly
suggest that you read through the instructions completely before beginning construction.This will give you a good idea of the construction
sequence and eliminate many questions you might have if you did not read the manual prior to starting the actual construction. Due to the nature
of this design,this airplane is not intended for a beginner’s first model and the instructions are written with this in mind. We assume you have a
working knowledge of airplane and radio terminology.
The first thing you should do before beginning assembly is to check the contents of your kit against the parts list on pages 4 and 5. If any parts
are missing,contact your dealer immediately for replacement.Customers in the United States and Canada may contactAce Hobby Distributors at
116W.19th Street,Higginsville,MO 64037 [phone] for replacement parts.Under no circumstances can a kit be returned if assem-
bly has already been started.
P.S. Fred Reese was a dear friend. The Cloud Dancer is the first in a line of re-releases of his designs since his untimely death.We are proud to be
able to continue to offer his fine airplanes so we can keep his name alive in our small way.
Tom Runge,Ace Hobby Distributors,Inc.
Experienced pilots who want to maximize their enjoyment of the
Cloud Dancer 40 should consider installation of the optional retracts.
The instructions have complete details.
See your hobby dealer for addition information on these 40 sized
retracts,ThunderTiger part number 3007.
You will also need a 180º retract servo that is compatible with your 5
or more channel radio system.
OPTIONAL RETRACTS
TTR3007
A checklist is also provided on the next page which will
make shopping for these items easier.
OTHER ITEMS REQUIRED
FOR ASSEMBLY
Radio - A 4-channel radio with four standard servos is required.
(If you are installing retracts, you need a radio that has at least 5
channels and a 180º Retract Servo that is compatible.)

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RECOMMENDEDTOOLS & MATERIALS
Adhesives - You will need two types of adhesives for this ARF -
Epoxy and Instant (cyanoacrylate) adhesives.We recommend that you
purchase both 5-minute and 30-minute epoxy to cut down on
assembly time,but you can get by with only 30-minute epoxy if time
is not important.You will also need a small bottle of both“Thick”and
“Thin”instant adhesive.
Tools - Model assembly can be much easier if the proper tools are
used. Therefore, we have included in our checklist to the right,
a complete listing of all the tools we used to assemble our prototype
models. As you will notice, many household tools can be utilized
during construction.
Engine - The Thunder Tiger PRO-46 is the ideal engine for this air-
plane.It is a quiet running engine that is easy to start and require no
special break- in period,is very easy to maintain,and will last for years.
Flight Equipment - There are several “support” items that you will
need to purchase in order to get your engine running and your plane
in the air.These are listed at the bottom of the page.
Comprehensive Items Needed Check List
❏4-Channel Radio with 4 Standard Servos
❏5-Minute Epoxy (4 ounces or so)
❏30-Minute Epoxy (4 ounces or so)
❏“Thin”Instant Adhesive (1/2 ounce)
❏“Thick”InstantAdhesive (1/2 ounce)
❏Hobby Knife and Blades
❏Epoxy Mixing Sticks and/or Brushes
❏Sandpaper (150 grit)
❏MaskingTape
❏RubbingAlcohol
❏PaperTowels
❏Ruler
❏90 DegreeTriangle
❏Waxed Paper
❏Fine-Point,Felt-Tip Pen
❏Misc.HouseholdTools
❏Drill and Bits (1⁄16",5⁄64",3⁄32",5⁄32",3⁄16")
Flight Equipment
❏Foam Rubber Padding for the radio
❏Stick on Lead Strip for balancing the plane
❏3 or 4 Props (see engine instructions)
❏10%-15% Glow Fuel
❏Fuel Pump or Bulb
❏Electric Starter or“Chicken Stick”
❏Glow Plug Clip and Battery
❏Extra Glow Plug(s)
CARR
Y
ABreakthrough in Field Equipment!
The CarryMaster’s“Organization Plus”allows you to transport all your
field essentials in a rugged and compact case that will fit about any-
where in about any vehicle. A complete“turn-key”combo is available
as well as the case by itself.
Combo contents include:
•3liter fuel cell
•12v starting battery/charger
•glow starter/charger
•12v HD starter
•4-way wrench

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PARTS DRAWINGS
AS6128 Fuselage
AS6134 Pushrods
3282W Spinner Set
AS6136 Decal
AS6129Wing Set
3262 FuelTank
PE0009 Hardware Set
LeftWing(1) RightWing(1)
Center Rib(2)
TrimTape L(1)
TrimTape S(1) Wing Joiner(3)
Torque Horn(2) CA Hinge(6) Wing Protector(1)
Aileron ServoTray(1) Wing Bolt(2) Washer(2)
Stab Pushrod(1)
Rudder Pushrod(1)
Plastic GuideTube(1)
Aileron Pushrod(2) 0.05" Metal PianoWire(1)
Clevis(5)
Decal
Self-Tapping Screw(2)
Spinner Back Plate(1)
Spinner(1)
Pushrod Connector(1) AllenWrench(1)
2mm Hex Nut(2) 3mm x8mm Set Screw(1)
IMPORTANT
Please check the contents of your kit box with these part sketches before beginning
construction.This will not only familiarize you with the parts and their names,but it
will also give you a head start in the unlikely event that you are missing a part.
Parts are not necessarily drawn actual size!
Retract Servo
Mount(2)
Fuselage(1)
Rubber Stopper(1)
Straight Nipple(1)
SiliconeTube(1)
Cap(1)
Clunk(1)
90-degree Nipple(1)
180cc (6oz)
180cc FuelTank(1)

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PARTS DRAWINGS
AS6130Tail Feathers
AS6133WheelWell
3296Wheel
PE0585Wheel Pant Set
3102Adjustable Engine Mount
AS6131 Cockpit/Canopy
AS6137 Retract Hardware Set
AS6135 Landing Gear Set
AS6132 Cowl
AS6007Tail Gear Set
AS6100 Control Horn
57mm 2 1/4"Wheel(2)
6/32 x18mm
screw(4) 3mm x 15mm
Self-Tapping Screw(4)
Beam(2,left/right)
Engine Mount Plate(1)
WheelWell(2)
Tail Gear(1)
3mm x 8mm
Self-Tapping
Screw(1) Collar(1) 3mm x 3mm
Set Screw(1)
TailWheel(1)
3mm x 15mm
Self-Tapping Screw(1) 2mm x 8mm
Self-Tapping Screw(8)
Cowl(1) Back Plate(3) Control Horn(3)
2mm x 15mm Screw(6)
3mm x 3mm
Set Screw(4)
3mm x 8mm
Self-Tapping Screw(8)
Mounting Strap(4)
Collar(4)
Strut(2)
Landing Gear Mount(2)
Mounting Strap(2)
3mm Locknut(4) 3mm x 5mm Screw(4)
Wheel Pant(2,L & R)
2mm Nut(2) Steel Clevis(2) 3mm x 3mm
Set Screw(2) 3mm x 10mm
Retract Mounting Screw(8) Collar(2)
Linkage Rod(2)
Parts are not necessarily drawn actual size!
Replacement parts must be ordered by Set Number
H.Stab/Elevator(1) V.Fin/Rudder(1)CA Hinge(7)
Cockpit(1)
Canopy(1)
TrimTape(1)

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WING ASSEMBLY
I. Pre-Assembly Notes
1. Please assemble your model according to these instructions.
Do not attempt to modify or change in any way as doing so may
adversely change its flying characteristics.
2. Before you begin, please check the entire contents of this kit
against the parts list and photo to make sure that no parts are
missing or damaged.This will also help you to become familiar
with each component of your plane.
3. Each step of these instructions is preceded by a box which can
be checked off as you complete the step.This will allow you to
follow your progress and quickly find your starting place after any
interruptions or breaks.
Note: Your dealer cannot accept kits for return if
construction has begun.
II. Decide On Retracts
❏ Before assembling the wing,you must decide whether or not you
are going to install the optional retracts. If you fly off a grass field,we
recommend you stay with the stock fixed gear. Instructions are
provided for either event.
III. Wing Assembly (Fixed Gear)
❏ To hinge the aileron to the wing,begin by removing it from one of
the wing panels. Install the“CA”hinges into the aileron and useT-pins
to hold them in place while inserting the hinges in the wing (or sim-
ply us thin CA and permanently glue them in place in the aileron.)
❏ Install the aileron onto the wing,making sure the arm of the torque
rod goes into the hole in the aileron.Keeping the gap to a minimum,
wick thin CA onto the hinges,making sure you get glue on all surfaces.
After the glue“fires”,firmly tug on the aileron to make sure it is secure.
Repeat for the other wing panel.
❏With a wing panel upside down on your work surface,cut away the
material that covers the landing gear block area. With the landing gear
block centered over the hole,mark around the block. Next,cut away
the balsa sheeting from this area.
❏ Note that each landing gear block has a hole pre-drilled. This hole
goes to the center of the wing. With this in mind, securely glue the
landing gear blocks in place with 30 minute epoxy. Wipe away any excess.

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WING ASSEMBLY
❏ Locate the three plywood dihedral braces. Using epoxy or thick
CA,glue and clamp these pairs of pieces together. Keep the edges of
the pieces lined up and wipe off any excess glue. Also laminate the
two center ribs together.
❏ Before gluing the two wing halves together,trial-fit the wing joiner
into both wing panels. If it is not easy to slide into the wing, sand it
until it will. To fit properly, note that the wing has an upward“bend”
in it, called dihedral. While fitting, also have the double center rib
temporarily in place.
❏ With 30 minute epoxy,liberally coat all sides and edges of the wing
joiner and slip it into one wing half. Now coat the both sides of the
double center rib where it will join to the wing halves.
❏ Join the two wing halves and firmly press wing panels together.
Wipe off any excess epoxy with a paper towel and rubbing alcohol.
Make sure the two panels are accurately aligned with each other and
hold together with several strips of masking tape.
❏Place the servo tray on the top surface of the wing. Line it up with
the removed area in the center rib. Mark around the outside of the
servo tray with a felt tip pen.
❏ Use a sharp knife to score the covering material where marked
around the OUTSIDE of the tray. Remove the covering material to
expose the wood underneath. Use thick CA or epoxy to glue the servo
tray securely in place.
❏Use a sharp knife to cut through and remove the covering materi-
al and balsa on the INSIDE of the servo tray.
❏Install your aileron servo.
❏ Install the linkage between the servo and the aileron torque rods.
It consists of a nylon horn that is threaded onto the torque rod so a
few of the threads are exposed at the top,a threaded rod with a nylon
clevis screwed on one end. (Screw it on so 1/2 the threads still
remain.) To hook to the servo arm,put a“Z”bend on the other end at
the proper distance so the aileron remains in neutral.
❏Strips of covering film are provided to trim out the center joint. You
will need to use a covering iron or a household iron to secure the film.

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RETRACT INSTALLATION
❏ Epoxy the wing halves together, making sure you coat all sides of
the dihedral brace plus where the ribs join. Use some masking tape to
hold the wing together as the glue sets.
❏Cut away the balsa sheeting to expose the retract servo location.
Also cut away for the aileron servo opening. Glue the aileron servo
tray in place,removing the covering film first..
❏ Remove the covering material that covers the landing gear hole in
the bottom of the wing. Next cut away the sheeting to accommodate
the plastic wheel well. It is indicated in this photo by dotted lines.
❏Trim the plastic wheel wells as shown.
IV. Retract Installation (Optional)
❏See page 2 for a discussion on the retracts we recommend.
Begin by hinging the ailerons to the wing panels as shown in the
section on fixed gear.
❏Remove the forward area that houses the retract servo from the
root rib and the plywood center rib;do so for both left and right.
❏Glue the ply center rib onto the root ribs for both left and right
wing panels.
❏Laminate the three ply dihedral braces together.
❏Test fit the dihedral brace into both wing halves and sand as needed
for a good fit.

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RETRACT INSTALLATION
❏Glue the wheel wells into the wing using a compatible glue such as
“Zap-a-dap-a-goo”,RC 56,or“Shoe-Goo”.
❏Drill pilot holes for the retract assemblies.
❏ With a pushrod attached to the retract assembly,move it into
position and mount to the hardwood blocks. Pushrods not provided.
❏Glue mounting blocks for the retract servo in the opening.
❏Mount the retract servo and bend the pushrods as shown for
proper clearance.
❏Connect the pushrods to the retract servo arm with“Z”bends or
“EZ”Connects.
❏Install the wheels and check for proper operation.

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FUSELAGE
V. Wing Bolts
❏ The wing is attached to the fuselage using two bolts and blind nuts.
Begin by installing the blind nuts in the wing mounting plate which is
to the rear of the wing opening in the fuselage.
❏Glue the furnished plastic plate on the bottom of the wing.
Center it on the wing and line it up with the trailing edge.
❏Drill two 3⁄16”holes through this plate in the wing at the locations
indicated (1” from center, 5⁄8”from rear). Now the wing can be
mounted to the fuselage using the bolts furnished.
VI. Fuselage
❏ Locate the pushrods for elevator and rudder. At the aft end of the
fuselage,find the pushrod exit holes and remove the covering for the
elevator on both sides of the fuselage. Next locate the hole for the
rudder pushrod on the left side of the fuselage and remove the cover-
ing. Next install the elevator pushrod first and the rudder pushrod last.
❏Locate three metal clevises,two for elevator pushrod and one for
rudder. Next cut three pieces of fuel tubing,make each piece of fuel
tubing about 1⁄4" in length. This will keep the clevis from coming
detached in flight.
❏Temporarily mount the wing to fuselage, so that stabilizer can be
properly aligned. Measure from stab tip to wing tip on both sides. This
will ensure that the stab is square in the saddle. Also check the
alignment of the stab horizontally. Once satisfied with the position of
stab, mark it so the covering can be removed on the bottom side of
the stab. When removing the covering from the bottom of the stab,
be very careful not to cut too deep with your exacto knife,as this will
weaken the stab.
❏Cut away the covering from notched area on top of the stab and
prepare to mark the covering that will be removed for the vertical fin
to be glued into place. Align vertical fin and draw a line on both sides
of the fin. Now remove the covering between the lines as shown in
the picture. Mix up a small amount of 30 minute epoxy to install the
stabilizer and fin to the fuselage. Recheck the alignment to ensure that
the stab and fin will be in the correct place when the epoxy cures.
1”
5/8”
a
a=b
b