THUNDER TIGER Fun Tiger Extra User manual

WARRANTY
Thunder Tiger Model Company guarantees this model kit to be free from defects in both material and
workmanship at date of manufacture. This warranty does not cover any components damaged by use
or modification and in no case shall Thunder Tiger’s liability exceed the original purchase price of the kit.
Thunder Tiger also reserves the right to change or modify this warranty without notice.
Since Thunder Tiger Model Co. has no control over possible shipping damages, construction techniques
or materials used for construction by the modeler, no liability can be assumed nor accepted for damage
resulting from the use by the user of the final user-assembled product. By the act of using this user-
assembled product, the user accepts all resulting liability. If the buyer is not prepared to accept this lia-
bility, he should return this kit in new and unused condition to the place of purchase for a full refund.
Assembly Instructions
&
No. 4517
No. 4518

2
INTRODUCTION
INTRODUCTION
All of us at Thunder Tiger want to thank you for choosing the best-looking, lightest-weight,
and best -flying ARF available in this category of R/C, the profile fuselage Fun Fly. This kit features
state-of-the-art engineering that provides quick and easy assembly of a strong, yet lightweight airplane
that will provide you with an enjoyable experience. The Fun Tiger will do every maneuver in the book!
To gain the most from this airplane kit, it is important that you read the instructions thoroughly and
then follow them exactly. This instruction manual has been written with an inexperienced modeler in
mind, but includes many hints and modeling tips that even experienced modelers can benefit from.
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.
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 contact Ace Hobby Distributors direct-
ly at 116 W. 19th Street, Higginsville, MO 64037 660-584-6704 for replacement parts. Under no cir-
cumstances can a kit be returned if assembly has already been started.
Introduction . . . . . . . . . . . . . . . . . . . . . . .2
Other Items Required . . . . . . . . . . . . . . .2
Items Needed Check List . . . . . . . . . . . .3
Parts Sketches . . . . . . . . . . . . . . . . . . .4-5
Pre-Assembly Fuselage . . . . . . . . . . . . .6
Pre-Assembly Wing . . . . . . . . . . . . . . .7-8
Pre-Assembly Hinging . . . . . . . . . . . . . . .8
Landing Gear . . . . . . . . . . . . . . . . . . . . .9
Install the Engine . . . . . . . . . . . . . . . . . .9
Install the Fuel Tank . . . . . . . . . . . . . . . . .9
Install the Linkage
. . . . . . . . . . . . . . . . . . . . . . . 10-12
Set-Up . . . . . . . . . . . . . . . . . . . . . . . . .13
Flying Hints . . . . . . . . . . . . . . . . . . . . . .13
Balance . . . . . . . . . . . . . . . . . . . . . . . .13
Pre-Flight Checks . . . . . . . . . . . . . . . . .14
Safety Precautions . . . . . . . . . . . . . . . .14
Post-Flight Check List . . . . . . . . . . . . .14-15
A checklist is also provided on the next page
which willmake shopping for these items easier.
TABLE OF CONTENTS OTHER ITEMS REQUIRED
FOR ASSEMBLY
Radio - A 4-channel radio with five standard
servos is required. To achieve the maximum
maneuverability from this plane, we recommend
you use a computer-based radio for
elevator/flapperon mixing.

3
ITEMS NEEDED
Adhesives - You will need two types of adhe-
sives for the Fun Tiger - 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 house-
hold tools can be utilized during construction.
Engine - The Thunder Tiger GP-42, PRO-40/46
and F-54S are the ideal engines for this air-
plane. These quiet-running engines are easy to
start, require no special break-in periods, are
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
❏40 Size Engine
❏4-Channel Radio with 5 Standard Servos
❏5-minute Epoxy (4 ounces)
❏30-minute Epoxy (4 ounces)
❏“Thin” Instant Adhesive (1/2 ounce)
❏ “ Thick” Instant Adhesive (1/2 ounce)
❏Hobby Knife and Blades
❏Epoxy Mixing Sticks and/or Brushes
❏Sandpaper (150 grit)
❏Masking Tape
❏Rubbing Alcohol
❏Paper Towels
❏Ruler
❏90 Degree Triangle
❏Waxed Paper
❏Fine-Point, Felt-Tip Pen
❏Misc. Household Tools
❏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)

4
PARTS SKETCHES
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.
If parts are missing, call [phone].
Parts are not necessarily drawn actual size!
Left Wing (1) Right Wing (1)
Spinner (1)
(2)
Tapping
Screw (2)
Backplate (1)
Wing Joiner (2)
Balsa Stick (2)
Balsa Hatch (2)
Dowel (1)
Wood Screw (4)
WING SET #AS6009
(#AS6002)
FUSELAGE #AS6008
(#AS6001)
HORIZONTAL TAIL #AS6011
(#AS6004) VERTICAL TAIL #AS6010
(#AS6003) WHEEL #3256 SPINNER #3284W

LINKAGE BAG #AS6006
5
PARTS SKETCHES
Parts are not necessarily drawn actual size!
Replacement parts can be ordered by Set Number Only.
Individual parts not available.
Screw (8)
Landing Gear (2)
Socket Screw (2) Allen Wrench (1)
Horn &
Backplate (2 pr)
MAIN LANDING GEAR #AS6005 CONTROL HORN
#3151
Screw (2)
3mm Hex Nut (4) 4mm Hex Nut (4)
FUEL TANK #3261 TAIL WHEEL SET #AS6007
Inner/Outer Nyrod (2)
Plastic Guide Tube (1)
180cc Tank (1)
Cap (1)
Clunk (1)
Fuel Stopper (1)
Silicone Tube (1)
Straight Nipple (1)
90˚ Nipple (1)
Pushrod Clamp (4)
Clevis (4)
2mm Nut (1) Set Screw (1)
Set Screw (1)
Wheel Collar (1)
Tail Gear (1)
Piano Wire (1)
Z-Bent
Threaded End (2)
“EZ” Connect (1)
Threaded Stud (2) Allen Wrench (1)
Wood Screw (4)
Wood Screw (2)
Tail Wheel (1)

6
PRE-ASSEMBLY
INTRODUCTION
1. The Fun Tigers are designed for the experi-
enced R/C pilot. If you do not yet have the skills
to fly this outrageously maneuverable machine,
set it aside until you have progressed through
the trainer and intermediate stages of R/C flight;
you will then be ready for this plane.
2. 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.
3. Before you begin, please check the entire
contents of this kit against the parts list and
drawings to make sure that no parts are missing
or damaged. This will also help you to become
familiar with each component of your plane. If
you find that any of the parts are either missing
or damaged, please contact your dealer imme-
diately for replacement.
Note: Your dealer cannot accept kits for
return if construction has begun.
Note: Each step of these instructions is pre-
ceded 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.
The following instruction manual
depicts the Fun Tiger Extra. If you are
building the Fun Tiger G-200, it builds
exactly the same; just disregard the dif-
ferences in the color scheme.
PRE-ASSEMBLY-Fuselage
1
❏Using a sharp modeling knife, cut away the
covering film from both the wing joiner slot and
the 1/4”D alignment hole in the wing area on
both sides of the fuselage.
2
❏ Also cut away the film at the rear of the fuse-
lage where the stab slot is. Notice that this
reveals the balsa tail post between the flaired
part of the stab slot. Use a razor saw or repeat-
edly cut with a hobby knife to remove the tail
post in this area.
3
❏Locate the full size drill template. Cut away
the paper where indicated. Locate it on the left
side of the fuselage and tape in place. Using a
center punch or an awl, mark and drill four 5/32"
holes for mounting the landing gear then mark
and drill three 5/64" holes for the tank mounting
wires. Be careful to keep the drill perpendicular
to the fuselage.
4/5
❏Position your engine in the cut-out area in the
front of the fuselage so the spinner will clear the
nose by about 1/8". Firmly holding the engine in
place, mark the four engine mounting hole loca-
tions. Drill four 5/32" holes where marked,
being careful to keep the drill perpendicular to
the fuselage.
Using medium CA glue or epoxy, coat the
exposed wood in the fuselage’s engine slot for
fuel proofing.

7
WING ASSEMBLY
6
❏Drill 3/16” holes in the bottom of the rear of
the fuselage to accommodate the barbed pins in
the tailwheel mounting bracket. Locate the
holes using the bracket/tailwheel assembly as a
guide. Line up the bracket so the “tiller arm”
portion of the wire is flush with the rear edge of
the fuselage.
PRE-ASSEMBLY-Wing
7
❏Using epoxy, laminate the two plywood wing
joiners together. Clamp together keeping the
edges aligned; wipe off excess glue before it
sets. Allow to cure. When dry, sand all edges
of the joiner, removing any bumps or irregulari-
ties. Test fit the joiner into the slots of both wing
halves and trim as necessary for a good fit.
8/9
❏Observe that there is an open bay in the top
of each wing. This is where the radio will go. To
gain access to this area, you will need to cut
away the covering film.
Begin by cutting the film diagonally across
the bay with a sharp modeling knife from corner
to corner.
Fold the material down into the wing and
press it down so it sticks to the vertical edge of
the wing sheeting. Note there is a 3/16" wide
ledge on both sides of the opening; press the
material down to this ledge and use your finger-
nail to burnish the material into the corners of
the ledge. Trim away the excess material.
Permanently stick the covering material to the
edges with a heat sealing iron set on low tem-
perature.
10
❏Locate the two 3-1/8" X 4-5/8" balsa hatches
and the two 1/4" X 4-3/8" balsa hatch tongues.
Using thin CA, glue a hatch tongue along the
long edge of one of the hatches leaving 1/8"
overlapping the edge and centering it length-
wise. Repeat for the other hatch.
11/12
❏Put one of the hatches into place in the open
bay of one of the wing panels...the hatch tongue
is to fit into the rear edge of the opening; you
may have to do a bit of trimming on the tongue
for it to fit. With the hatch in position, drill a
1/16" pilot hole through both the hatch and the
plywood mounting platform about 1/2" from the
side and 1/8" back from the front edge of the
hatch. Remove the hatch and expand both
holes to 1/8". Now the hatch can be secured
with two self-tap screws furnished. Repeat for
the other hatch.
13
❏Locate the paper template for cutting the
pushrod/nyrod slots. Trim along the lines that
indicate the center and the rear of the wing. Put
the template on top of the left wing panel and
line up the edges...tape the template in place.
Using a sharp modeling knife, cut two slots in
the wing sheeting in the location indicated;
make a few shallow cuts instead of one cut

8
WING ASSEMBLY
all the way through. These are where the
pushrod and Nyrod will exit the wing when the
radio is installed. Repeat for the right wing
panel by putting the template on the wing
upside down.
PRE-ASSEMBLY-Cutting away
covering material
❏In the following steps, you will be cutting
away covering material in preparation for gluing.
You have to be careful here. When cutting way
the covering, you need to use a sharp modeling
knife and only score the film itself. DO NOT cut
into the wood below the covering. If you do, the
structure of the airplane will be compromised
and failure may occur. Use a felt-tip pen to mark
the cutting locations as instructed.
14/15
❏Begin with the fuselage/wing joint. Slip the
wing joiner into the slot in the fuselage and the
1/4" alignment dowel into the hole at the rear of
the wing location. It helps insertion if you round
over the edges of both the joiner and the dowel.
Slide both wing halves onto the wing
joiner/dowel until they butt up to the fuselage
side. Mark the fuselage around the outer
perimeter of wing. Remove the wing and care-
fully score the covering about 1/8" on the
INSIDE of these marks and peel off the cover-
ing to reveal raw wood at the wing/fuselage
joint. DO NOT GLUE THE WING IN PLACE!
YET.
6
❏Put the fin into place in the slot in the rear of
the top of the fuselage. Mark the fin on both
sides where it meets the top edge of the fuse.
Take the fin out and remove the covering mate-
rial about 1/32" below your mark.
❏Slip the stabilizer into its slot in the fuselage.
Using a ruler to center the stabilizer and a T-
square to make sure it is perpendicular to the
fuselage, mark where the fuselage meets the
stabilizer on the top and bottom. Slide the stab
out and remove the covering material about
1/32” on the inside of your marks.
PRE-ASSEMBLY-Hinging
❏In the following steps, you will be mounting
the control surfaces by gluing the hinges in
place. All of the slotting has been done for you,
so it requires very little work. Begin by test fit-
ting the ailerons to the wing, the elevator to the
stabilizer and the rudder to the fin.
17
❏To help prevent glue from restricting the
hinge action, put a small drop of oil on the
moveable part of each hinge, being careful not
to get any oil on the flat surfaces of the hinges.
Lay them on a paper towel to absorb the excess
oil.
18
❏We prefer to use 30 minute epoxy and do all
the hinging at one time.
The easiest way to accomplish this task is
to evenly coat the top and bottom surfaces of
one half of a hinge and slip it into its slot in the
control surface; do the same for the other
hinges in the control surface. This lets the con-
trol surface itself be your holding fixture. Then
coat both sides of the exposed half of all the
hinges. Next, slide the control surface in place,
starting at one end or the other.
Keep paper towels and some rubbing alco-
hol handy to clean up epoxy fingerprints on the
covering material before it sets.