THUNDER TIGER TTR4550 User manual

1
ThunderTiger G202-140 ARF Airplane (TTR4550)
Distributed in NorthAmerica byAce Hobby Distributors,Inc.• 116W 19th ST,Higginsville,MO 64037
Phone:[phone] • www.acehobby.com • email:[e-mail]
Assembly Manual
Wing Span: 70"
WingArea: 1022 in2
Length: 70"
Weight: 10-10.5 lbs
Engine: 1.08-1.6 2 Cycle
1.2-1.8 4 Cycle
Radio: 7 Channel w/6 Servos
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 lliability 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.
JE6328
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
PRE-ASSEMBLY NOTES
Congratulations on the purchase of one of our finestARFs to date. This scale replica of the famous Giles
G-202 is as faithful in its appearance as it is in its flight characteristics. Beautifully reproduced using balsa and
ply construction. Covered in durable and easily repairable UltraCote®,this plane is highly visible in the air
and strikingly recognizable on the ground.
Before beginning the assembly read the instructions thoroughly to give an understanding of the sequence
of steps and a general awareness of the recommended assembly procedures.
By following these instructions carefully and referring to the corresponding pictures,the assembly of your
model will be both enjoyable and rewarding. The result will be a well built, easy to assemble ARF model,
which you will be proud to display.
This G202-140 is designed for intermediate to advanced pilots, and this manual assumes a basic knowl-
edge of R/C model construction.
Before you begin,check the entire contents of your kit against the parts list and photos 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 contactAce Hobby Distributors,
Inc.,Customer Service (660-584-6704) immediately for replacements.
Please read the entire manual before beginning construction.
Neither your dealer nor Ace Hobby Distributors, Inc., can accept kits for return if construction has
begun.
Trial fit each part before gluing it in place. Make sure you are using the correct part and that it fits well
before assembling. No amount of glue can make up for a poor- fitting part.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .2
Items Needed Check List . . . . . . . . . . . . . . .3
Parts Sketches . . . . . . . . . . . . . . . . . . . . . . .4-5
WingAssembly . . . . . . . . . . . . . . . . . . . . . .6-9
StabilizerAssembly . . . . . . . . . . . . . . . . . .9-11
Elevator Servos . . . . . . . . . . . . . . . . . . . .11-13
Tailwheel . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Landing Gear . . . . . . . . . . . . . . . . . . . . . .13-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
FuelTank . . . . . . . . . . . . . . . . . . . . . . . . .15-16
Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
Switch & Receiver . . . . . . . . . . . . . . . . . . . .17
WingAttachment . . . . . . . . . . . . . . . . . . . . .17
Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Prop & Spinner . . . . . . . . . . . . . . . . . . . . . . . .18
ControlThrows . . . . . . . . . . . . . . . . . . . . . . . .18
CG,FlightTips . . . . . . . . . . . . . . . . . . . . . . . . .19
TABLE OF CONTENTS

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RECOMMENDEDTOOLS & MATERIALS
Adhesives:
Instant setting cyanoacrylate adhesive (thin CA)
Slower setting cyanoacrylate adhesive (medium CA)
5 Minute Epoxy (fast)
20-30 Minute Epoxy (slow)
R/C 560 Canopy Glue
Zap-A-Dap-A-Goo II™
Tools:
Model knife,T-Pins,1/2”vinyl tape
Small screwdrivers,medium screwdrivers
Lexan Scissors
Steel straight edge
Long nose pliers and diagonal cutting pliers
Drill and drill bits
Dubro 8-32 tap
Sanding block
Fine felt tip pen and soft lead pencil
Straight building board
R/C System:
Seven channel radio with one standard servo and
five dual BB high torque servos
Four 12" aileron extensions
One servo reverserY-harness
Engine:
2 cycle: 1.08-1.60
4 cycle: 1.20-1.80
Propeller (appropriate for engine type and
preferred performance)
Radio -A 7-channel radio with 5 high performance servos
and 1 standard servo is required.
Adhesives - You will need two types of adhesives
for the G202-140 - Epoxy and Instant (cyanoacry-
late) 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 CA adhesive.
Tools - Model assembly can be much easier if the
proper tools are used.Therefore, we have included
in our checklist to the left, a complete listing of all
the tools we used to assemble our prototype mod-
els. As you will notice, many household tools can be
utilized during construction.
Engine - The Thunder Tiger PRO-120 is the ideal
engine for this airplane.This quiet-running engine is
easy to start, requires no special break-in periods,is
very easy to maintain and will last for years.

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PARTS DRAWINGS
Main Landing Gear(1) Wheel Pant(L/1, R/1)
AS6149 Main Landing Gear
4mm Nut(4) 4mm Locknut(2)
Wing Bolt Plate(1)
AS6146 Main Wing Set
Wing Joiner(4)
4mm Washer(2)
Main Wing( L/1 R/1)
Belly Front Former(1)
Fiber Cloth(1) Dowel(2)
Wing Bolt(2)
AS6145 Fuselage
Fuselage(1)
2.3mm x 12mm Wood Screw(4)
AS6147 Horizontal Tail
stab./Elevator( L/1,R/1)
Carbon Tube(2)
2.3mm x 12mm
Wood Screw(4)
AS6148 Vertical Tail
Vertical Fin/Rudder(1)
Wheel(2)
4mm x 40mm
Socket Screw(2)
4mm x 16mm
Machine Screw(3)
AS6151 FRP Belly Pan
FRP Belly Pan(1)
PE0009 Hardware Set
(Sold in Pair)
2mm Hex Nut(1)
3mm x 3mm Set Screw(1)
Pushrod Connector(1)
Allen Wrench(1)
Canopy (1)
AS6152 Canopy
FRP Cowl(1)
AS6150 FRP Cowl
Mounting Ring(1)
2.3 x 12mm
Wood Screw(4)
Mounting Block(4)
Back Plate(1)
3mm x 12mm
Self-Tapping Screw(4)
No.3278W Spinner
720 c.c. Tank(1)
Fuel Stopper(1)
Cap(1)
90-degree Nipple(1)
Silicone Tube(1)
Nipple(1)
No.3272 Fuel Tank Set
Clunk (1)
No.3013 Swivel Ball Link Control Horn Set
(Sold in Pair)
2mm Hex Nut(15)
Back Plate(4)
2mm x 22mm
Screw(15)
Spinner(1)
Control Horn(6)

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PARTS DRAWINGS
No.3014 Pull-Pull System
Clevis(2)
Threaded End(2)
2mm x 8mm
Screw(2)
Bass Tube(8)
2mm Hex Nut(2)
Z-Bend End(2)
Cable(1)
No.3015 Scale Tail Gear Blind Nut(2, Installed in the Fuse.)
Tail Gear(1)
4mm x 20mm Sink Head Screw
Spring (2)
Control Horn(1)
E Clip(1)
Steering Shaft(1)
Steering Fork(1)
2.6mm x 26mm
Sink Head Screw(1)
Tire(1)
Tail Wheel(1)
Plastic Washer(2)
Wheel Spacer(1)
2.3mm x 12mm
Wood Screw(2)
No.3012 Anti Vibration Engine Mount
Mounting Beam(2)
TWasher(8)
Rubber(8)
Blind Nut(4) 5mmx40
Socket Screw(4)
Hex Wrench(1)
Spring Washer(4)
Eng Mounting Screw
6/32 x 20mm(4)
4mm x 20mm(4)
AS6154 Decal
AS6153 Piano Wire
Piano Wire(1)
No.3016 2.3mm Pushrod Set(Sold in Pair)
Dia 2.3mm(0.09") Pushrod (4)
Wire Guide(1)
2mm Hex Nut(4)
Clevis(4) 2mm x 8mm
Screw(4)

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WING ASSEMBLY
I. Mount Servos
❐With the wing panel upside down,locate the servo well and cut an
X from corner to corner using an Xacto knife.
❐Use a sealing iron to tack down the covering inside the servo well.
❐With the wing rightside up, locate the servo wire exit hole and
remove covering.
❐Attach the 12" aileron extension lead to the servo.
❐Install the servo in the wing. Use a servo arm instead of the
standard wheel.
❐Use a piece of clear tape to temporarily hold the servo pigtail to the
wing to prevent it from slipping back into the wing while you are
working.
II. Install Ailerons
❐Remove the aileron and insertT-pins into the centers of the hinges.
Install aileron onto the wing,removeT-pins,and apply thin CA to the
hinges (both sides).

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WING ASSEMBLY
❐Install control horns. Use a pen or marker to mark the positions for
the aileron control horn.
❐Drill out the holes as shown. Attach the control horn using the
enclosed bolts and control horn back plate.
❐Attach the Z-bend end of the control rod to the servo horn, then
attach the clevis to the threaded end and bolt it to the control horn. It
may be necessary to enlarge the hole in the control arm to allow the
Z-bend to fit.
III. JoinWing Panels
❐Locate the four dihedral braces and stack them,then mark an arrow
indicating the 'up' edge. Trial fit the braces in each wing panel. If
needed, sand the edges lightly so that the brace fits in each wing
smoothly.
❐Mix some 5 minute epoxy and laminate the four dihedral braces
together and clamp for 30 minutes.
❐Mix up some more 5 minute epoxy and glue the dihedral brace into
one of the wings and let it dry for 30 minutes.
❐Mix up an ample amount of 30 minute epoxy and apply to the inner
ribs on each wing panel and dihedral brace and make sure you have
plenty inside the wing joiner slot. Slide the wings together, tape
around the joint,and wipe off any excess epoxy. Set aside for 1 hour.
Note:The pushrod is 2.3mm(0.09"), you have
to locate the right clevis which has bigger hole
for pushrod to thread in.

8
WING ASSEMBLY
❐Using 5 minute epoxy, attach the front belly plate and wing
alignment dowels and let sit for 30 minutes.
❐Measure the top and bottom to find center of the wing hold-down
plate and draw a straight line between the two marks. This line will be
used to center the plate on the trailing edge of the wing panel.
❐Place the plate on the wing panel and mark around the three sides
with a pen or marker. Remove the plate and then remove the
covering material inside the lines. Be careful not to push through the
balsa;remove only the covering.
❐Apply a liberal amount of medium CA to the exposed wing panel
and place the holddown plate on it,holding it until the CA sets.
❐Turn the fuselage upside down and trial fit the wing assembly into
place to insure good fit.
❐Remove the wing and with a 1/4" drill bit drill through the existing
holes in the wing hold down plate and through the trailing edge of the
wing.
❐Epoxy the wing joint with fiber cloth both on top and bottom.

9
STAB,FIN & RUDDER
❐Install the blind nuts into the fuselage and bolt on the wings.
❐Install the bolts into the wings.
❐Run a bead of Zap-A-Dap-A-Goo II™ along the bottom surfaces of
the fairing balsa and along the front inside of the fiberglass. Attach to
the wing assembly and let sit overnight.
II. Install the Stab, Fin & Rudder
The G202-140 stabilizer can be installed two different ways:
removable stab and permanently mounted stab. In our construction,
we have opted for the permanent one.
❐Locate the two holes on each side of the rear of the fuselage and
remove the covering film from them.
❐Insert the two carbon fiber spars into the fuselage and center them.
Next slide one stab onto the spars on one side.
Removable Stab:
❐Locate and remove the covering material from the two holes on the
bottom of the stabilizers.
❐With a 1/16" drill bit drill one hole through the tubes and spars in
the holes on the bottom of the stab. BE CAREFUL NOTTO DRILLALL
THEWAYTHROUGHTHE STAB.
Note: Predrill the 1/16" holes in the stabs first;
when the stabs are in place you will know to
drill only through the first layer of the spars.

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STAB,FIN & RUDDER
❐With the stab and spars in place use a 3x10mm self tapping screw
to attach the stab to the spars. Repeat “Removable Stab” section for
other side.
Permanent Stab:
❐Insert the two carbon fiber spars into the fuselage and center them.
Next slide one stab onto the spars on one side.
❐Place the stab on the spars and against the fuselage. Mark around
the stab with a pen or marker and remove the covering material inside
the lines from the fuselage.
❐Mix up some 5 minute epoxy and glue the spars into the fuselage.
Let sit 10 minutes.
❐Mix up some 5 minute epoxy and glue the stabs to the fuselage and
let sit 15 minutes.
❐Remove the elevators and rudder,T-pin the hinges.
❐Remove the covering from the 1/2" wide flat stip at the top rear end
of the fuselage.
❐Carefully cut 1/2" deep on either side of the exposed area and
remove the block inside (this block should be loose from the factory
but is only there for strength during sanding and covering.).