Top Flite A6M2 ZERO Instruction Manual

BUILDING THE A6M2 ZERO
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TOP FLITE MODELS, INC

CONGRATULATIONS'
You now own the most accurate R/C Stand-Off Scalekit ever
produced
We at Top Flite hope thatyou willfindthis model the most
pleasant to build, inspiring to lookat and exciting to fly that you
have ever constructed
It ishonest to point out,however, thatwhile this model is no
more difficult- in factissimpler than most comparable kits to
make, R/C scale models generally are notfor the newcomer to
this hobby Previous modelingexperience and carefulattentionto
craftsmanshiparenecessary Even the "old hand"willdo wellto
study and follow the instructionsand guidance given in this book-
let.
It is-our aim to have you say "Thisisthe finestmodel I have ever
built".
TOPFLITE MODELS. INC
CONSTRUCTION OF THE A6M2 ZERO
BEFORE YOU START, READ THIS
The assembly sequence of yourTop Rite ZERO has been care-
fullydevelopedtohelpassure the correctalignment ofyourmodel
Utilize thecheck-offblocksas youbuild this will allow assembly
ofyourmodelinminimumtime
Before beginningan assembly step,read the instructionsto fami-
liarize yourselfwiththepartstobe used Findthepartsmention-
ed anddoublecheck themforproperidentificationandsize with
the plansDo notseparatepartsfromthedie cutsheetsuntilyou
need themThere aremachinedpartsinthekitwhicharenot
identifiedsuch asthe leadingedges, wingtips,etcThese parts
can be easilyidentifiedby checkingthepartsagainsttheplan.
We are sometimes asked which glues are best formodel construct-
ion The answerto thisdependsupontheparticularjobThis is
ournormalrecommendationFor allhardwoodtohardwoodor
hardwood-tobalsa joints,use white wood glue "Titebond" is
especially good, as itdriesfasterthanotherwhiteglues andis very
strongFor balsa-to-balsajoints,regularbalsa-wood cementsare
ample forthejob,althoughwhitegluecan be used here too.
Whichevertypeyouuse, rememberthatexcess glue is nosub-
stitutefora wellfittingjointUse a minimumof glue at all times,
and wipe offexcess glue thatsqueezes outofjointsbeforeit sets
hard,when set itisdifficultto remove, butif not removed it
could spoil the covering job.
IMPORTANTNOTETOBUILDER
Every model builtfroma kitis different,reflectingthelevel of
skill as well as thefavoredbuildingtechniques of themodeler
ultimatelythus,eachmodelis essentially theindividualcreation
of thatbuilder.
Changes andvariationstakeplace in buildingsothatwhile Top
Flite supplies most essential buildingmaterials,theend product
isthe creationof thebuilder
Therefore, Top Flite assumes noresponsibilityfortheperform-
ance of themodel, nordoes Top Fliteassume any responsiblity
ofany naturewhatsoever fortheloss of, or propertydamage
resultingfromthe operation of this model when itis completed
1
USECOMMONSENSE
When you havecompleted this model, you will have invested
considerable time, money and skillProtect this investment by,
1.Re-checking allcritical buildingpoints(center of gravity,
hingeing of controlsurfaces,strengthof stress areas,etc ).
2.Correctly installing theradio gear
3.Test and re-test the radio, all moving surfaces,landing gear
(ifretracts),condition ofbatteries, etc., BEFORE EACH
FLIGHT!
4.OBSERVE ACADEMY OF MODEL AERONAUTICS SAFETY
CODE, particularlythose rulesgoverningRADIO CONTROLL-
ED FLIGHT DONOT FLY WITHOUT BEING FULLY
INSURED
WARNING!!
Aradio controlled model is nota "TOY" Care and caution
must be takenin properlybuildingthemodel as well as in
the installationand use of theradiocontrolleddevice Itis
importanttofollow alldirectionsas toconstructionof this
kit as well as installationanduse of theengine,propellers
andradiogear The advice andassistance of a well exper-
ienced builderandpilot ishighly recommended Don't
take chances Improperbuilding,operationor flyingof
model could resultin serious bodily injurytoothers,your-
self, or propertydamage
CONSTRUCTION
SEQUENCE
Followeach stepinorderandputcheck marks in
theblocks as you completeeach phase described.
The fuselageplans come intwo sheets The smaller
must becut along the dotted line and glued (or taped)
to the larger plan at the dotted lines Beforeyou do
anybuilding of this kit, we suggest you spend a few
hours reading and studyingthis book and the plans.
When you are ready,tape ortack the fuselageplans on a
flat work surface Cover the working area of the plan with
MonoKote backing orwaxedpaper

Trace pattern of Fin sheeting (3 pieces on each side)from
plans onto 1/16" x 2-7/8" balsa. Cut out and glue together
as shown above. Make two.
Do same thing withStabilizer.Make two.
PinFin sheeting over plan. Glue R-7 inplace.Mark location
ofribs with softpencil.
Pin Stabilizersheetingoverplan. Glue 1/4"x 3/8" x 24"
inplace. Mark location of ribswith soft pencil.
Glue R-1. R-2. R-3 & R-4 ribs inplace.Apply glue only up
to 1/4"from frontof rib.
Glue top sheeting inplace. Again apply glue only upto1/4"
fromfrontof rib.
Glue shaped leading edgeto ribs only. When dry, glue plank-
ingto leading edge on both sides. Besure that the planking
forms to the shape of the leading edge.
Construct rudder as shown inillustration above and the plans.
Make stabilizerand elevatorsusing same procedures asis
described above._______
Glue F-2A-2'sto F-2A-1 and F-3A-2 to F-3A-1. Epoxy
F-1A(PLY), F-2A ASSEMBLY and F-3A ASSEMBLY all
together.
Glue former halves F-5A thru F-16A together, using plans
to measure correct width.
Pin notched strips(sometimes referred to as "crutch strips")
down over plans, locate frominner lineas the outer edge
of the stripwillbetrimmed offlater on.
Measure, cut and glue 1/4"SQUARE spacers inplace. Glue
1/4"x 1/2"SPACER and F-23 inplaceat rear.
Glue formersF-5Athru F-14Ainplace. Be sure formers
are perpendicular to notched strips.
Glue two F-22's inplace so they are 1/16"fromouter edge
ofnotched strip. Glue F-16A to F-22's and notched strip.
Glue F-17 in place.
Glue two pieces of 1/8"SHEET togetherandcuttofit for
cockpit floor.
Glue four 3/16" x 3/8" LONGERONS into notches in
formers.

Cut notchinrear centerof stabilizer for clearance for elev.
control horn movement (see plan).
Epoxy elevator control hornto stabilizer atBRASS TUBING
ONLY!
Epoxy stabilizer to fuselage. Check alignment inalldirect-
ions.
Cut hole instab planking for fin leading edge and epoxy fin
place.Check alignment inall directions.
Drill holes for controlhorns inrudder and bothelevators.
andthen "Vee"notch. Make openings forplastichinges.
Attach rudder controlhorn to rudder with epoxy.Attach
rudder to finand epoxy brass tubing (only)torear of fin.
Attach elevators to stabilizer.
Glue R-9 inplace. Fit 5/8" x 1-3/8" FILLET BLOCKS to
each side of rudder. Shape as required.
Fuselage canberemoved from plans.
Carefullyposition wing saddle assembly inposition onin-
verted fuselage halfand glue.
Epoxy former F-4B to front of wing saddle, to notched
strips and to motor mounts. Epoxy F-1BFirewallassembly
over motor mounts and to F-1Aassembly. Make sure fire-
wallsare flushand true inboth planes. Epoxy motor mount
support blocks inplace.
Make and glue all remaining formers (F-10Bthru F-16B) i n
position on notched strips.Glue 3/16" x 3/8" LONGERONS
inplace[F-1Bassemblyto F-4B and F-10B to F-15B(or
F-16B)].
Bend TAIL WHEEL WIREas shown onplans.Over the
straight end, assemble a collar,the nylon tailwheelbracket,
F-20(PLY)(afterdrillinghole)and another collar.
Make two supports forF-20(PLY)fromscrap1/8" balsa and
glueinto position. Cut the 3/8" x 5/8" x 3-1/2" long balsa
block into two pieces to fitin between F-16B and F-17.
Glue the pieces inplaceand rouqh to shape only.
Laminate F-1B(PLY), F-2B and F-3B firewall as described
for F-1A assembly. Set aside to dry.
EpoxyF-19(PLY)doublers to insides of F-18 pieces.
Glue formers F-5B. F-6B. F-7B, F-8B and P-9B into theslots
inthe two F-18 pieces.
Epoxy 1/2"x 1-1/8"MOTOR MOUNTS tothe insides of
F-18's and F-5B and F-6B as shown. Motor mounts are to
extend out 4-3/8" fromends of F-18's.
Cut3/8"x 1-1/8"x 1-1/2" long maple block inhalf to make
two pieces 3/8" x 3/4" x 1-1/8". Epoxy these pieces into
thecut-outs inthe F-19(PLY)'s.
Trim andgluea 1/8"x 7/8" x 30"STRIP to each side of
fuselage between the notched stripand firstlongeron.
Fit and glue a 1/8" x2-7/8"(or 3") x 30"SHEET between
next two longerons, on each side. Wood can beformedto
compund shape by wetting outside only. Hold in place with
pins, tape and/or rubber bands whileglue is drying.
Finish top with 1/8"x 3-3/4"(or 4") x 24" SHEET. Leave
opening at cockpit area.(F-7Ato F-9A).
All seams should bein the approximatecenter of each long-
eron. Allsheetingis done on a "Fit and try"basis.
3

Install elevator and rudder servos. Make and rudder pushrods.
Check allcontrol surfaces forfreeand proper operation. Safety
all clevisesnow as they are hard to get at once the fuselageis
entirely sheeted.
Glue 1/8"x 7/8" x 42" BALSA toeach sideas shown.
Fit,formand glue 1/8"x 2-7/8"(or 3") x 42" SHEET nextto
7/8" wide pieces.
Pit, formand glue 1/8"x 3-3/4"(or4")x 24"SHEET inlast
opening.
When shellsare dry, trim carefullyaround wing opening. Plank
(cross grain) openings from over formers F-4B thru F-10B with
1/16"balsa sheet.
Glue 1-1/8" x 2-1/2" x 2-3/4" TAILBLOCK inposition.
Carve and sand to shape. Sand entirefuselage, cutting down
raised edges ofnotched strip until flush with sheeting
For access to interiorof fuselage,cut out formers F-5B, F-6B,
F-7B, F-8B and F-9B frombetween F-18pieces.
Tape 4 pieces of 3/32" x 2-7/8" x 30" Balsa and two pieces of
3/32" x 2-7/8" x 15"BALSA together as shown above. Make
two sets.
Turn them over, open upslightly, and apply glueto joints. Lay
onflatsurface,withweights, until dry.
Cuta triangular piece, as shown shaded above, off of each
piece and SAVE.
Make two more sets, using the triangle, three 3/32" x 2-7/8" x
30"and two 3/32" x 2-7/8" x 15"foreach set.
Cover wing plan with MonoKote backing.Pinoneassembled
over outlineon plan.
GlueribsW—3thruW—11to spar, pinning thru feet of ribs,
checking to besure ribs are perpendicular.
Glue W—22 to front of each rib and pin.
Glue 7/16" THICK x 28" LONG TAPERED piece to back of
ribs and pin.
Glue upper spar inposition inrib notches.
When wing isdry,takeDIHEDRALGUIDE as shown above,
mark linesand cutoff spars, W—22andtrailing edge. Unpin
from plan.
Build opposite wing panel inexactlysame manner.
Glue W-3B(PLY) and W-3C(PLY) to W-3 RIBS. Make one
left hand and one right hand.
Glue W-5B(PLY)and W-5C(PLY)to W-5 RIBS. Make one
left hand and one right hand.
Cut four pieces of 1/4"x 1/2" BALSA stripsto 12-9/16"
long.Taper one end of each piece as shown.
Glue these strips to 1/4"x 1/2"x 30"SPARS, 15-1/8" from
oneend of each stripas shown. Leave excesslength onspar
to aid inpinning down. Make foursets.
4

Glue W-2C inplace on W-2B rib.Cut out one W-1B to same
length as W-2C as shown above (both W—1A'S if flap servo
is tobeused).
Epoxy 1/4"x 3/8" SERVORAILS inplaceusing servo as guide
for spacing. Installservo(s).
Make CONTROL WIRES as shown above (ball link connectors
arerecommended at servoend).
Glue W-8B inplace onW-8 rib.Glue W-9B inplace.
Mount BELLCRANKASSEMBLY(see plans)to W-12(PLY)
and epoxythisassemblyon W—8Band W—9B.
Plank top of wingpanel that is stillpinned down.
Remove wingfrombench and pin down oppositewingpanel.
Repeat plankingprocedure on thispanel. Unpin and remove
allrib feet.
Epoxy L.G. KEYBLOCKS to W-3 ribs. Epoxy GROOVED
L.G.BLOCK inrib notches. Locate fromplans. Drill7/32"
dia. hole to lineupwithgroove in key block
Locate and cut openings forcontrolwiresand main L.G.
wires, inwing planking. Plank both bottom wing panels.
Glue WING TIP blocks together and saw to outline. Glue
wingtips to wings, and shape.
Shape leading edges per plan. Sand wing allover.
Hinge ailerons permanently to wing. If flaps are to be oper-
ating, hinge them permanently, otherwisecement them in
place. Connectcontrolsto ailerons(andflaps).
Glue W-21 to center of 3/4" faceof 3/8" x 3/4" STRIP.
Mark location of each rib fromthe plans. Cut 3/32" x 3/8"
BALSA to length foreach rib, and glue them inplace top
and bottom. When dry,taper ribs with sandpaper blockor
razor plane. Make two ailerons.
Bevel frontof leading edge as shown. Install three NYLON
HINGES. See plans forinstructions.
Glue W—28(PLY)'sinplace top and bottom. Location of
W-28(PLY)'sdetermine L.H. orR.H. aileron.Make one each.
Install NYLON HORNS with #2-56 x 1/2" R.H.M.S.
Leave last wing panel built pinned to work table. Joinwing
halvestogether using W-16(PLY)JOINERS and slow drying
epoxy.Block upopposite wing panel for correct dihedral.
Epoxy W-17(PLY)'s to W-16(PLY)'s.
Crack W-13(PLY)and W-14(PLY)incenter to conform to
angle of leadingedge. Epoxyinplace as shown.
Shape 17/32" x 1-3/16" x 7" BALSA BLOCK to conform to
shape of trailingedge. Epoxy inplace. Epoxy W—18(PLY)to
thisblock.
Glue two W-1A's and two W-1B's together. Epoxy them in
place inwingasshown.
Assemble HARDWOOD BLOCK, W-2D's,W-19's and W-3D's
as shown above. Filler wedges aremade fromscrapbalsa.
5

Again the decisionto use landing gear retractsmust bemade before
construction begins Construction provisionshave been built into
the model forretractsThere is room inthe center of the wing,
foreward of the main spars, fora servo (mechanical retracts)ora
servo and valve(pneumatic retracts)The airsupply tank (pneum
system) islocated inthe fuselage Be sure the tank(s)and airlines
DONOT INTERFEREwiththe pushrod operation The model
canbebalanced with the wheels upordown as the fore and aft CG
remains the same
Thisplane isdesigned to have operating flapsifdesired The flaps
willhave to behinged and control horn added, instead of fastened
solid as shown on plans Provisionshave been made inthewing
for the additionalservoThedecisionto have operating flapsmust
bemade before the wing construction isstarted
Drill 1 /4" diax 1 3/4" deep hole inleading edge incenter of
wing Install 1/4"DIA x 2" LONG DOWEL withepoxy
Dowel should stickout at least1/4" Sand slightradiuson
end of dowel
Epoxy faceof F—21 (PLY)and slip over dowel with epoxy
away fromwing Do not get epoxyon dowel Put the wing
with F—21(PLY)inplace on the fuselageand aligncarefully
Temporarilyfastenitdown Thiswillcorrectlylocate the
F-2KPLY)on the fuselage
When the epoxyhas set and while thewing is still fastened
down, drilltwo 1/8"DIA holes thruwingand thru fuselage
blocks See plans forlocationdimensions
Glue F-10C to wing only(notto fuselage)Glue F—9C on
wing See plan forlocation Maketwo crosspiecesfromscrap
1/8"stock Sheet overthisareawith1/8" softsheeting
Remove wing Tap fuselage holes with #8-32 self tapping
screw furnished Drill wingholes out to 11/64" DIA for
screw clearance Cut notches inplanking forscrew head
clearance
Drill holes infirewall at properlocations for throttle and
mixturecontrols and fuel line Installengine—60to 90re-
commended Attachfuel line Installthrottle andfuel mixture
control cables Check forfreemovement
Installthe radioequipment (receiver,battery, servos, etc ) as
perthe manufacturers instructions
Make cut outs in FRONT COWL forexhaust,glow plug,etc
Cement to rear cowl and sand lightly with400 gritpaper
prior to painting
Attach W-26(PLY)L.GDOORS to main landing gear wire
as shown on plans , Installmain wheelsand tailwheel
Cover the model (exceptcowl)withcolored MonoKote, or
orcover the model with CHROME MONOKOTE, paint as per
color desired and then scribepanel outlines
Paint cockpit withflatblack Install pilot (not furnished) Trim
andinstall vacuum formed gunports and canopy See plans for
adhesives to use Apply markings furnished
Check radio carefully,including range check permanufacturers
instructions Check Center of GravityDo not deviate from
position shown on plans If youarenot a proficientR/Cpilot,
getthe help of one See warning on page 1 Save your plane-
avoid grief
Temporarily center the REARCOWL onfuselage sothat the
mounting holesareat 45°to the verticaland horizontalcenter
lines of the fuselage Mark location of holes with softpencil
Removecowl and drill 1/8" DIA holes thru at marks
Drill a 3/16" dia hole inthe center of each F 23(PLY)
piece Press a #4—40 blind nut firmly in each one
Fasten the rear cowl inplace with four #4-40 x 3/4"
RH M S Use the F 21 (PLY)withblind nut inside the
fuselaqe
With wing bolted inplace, form and fitwing fillets W-23,
W-24 and W-27 Allfilletson each side ofthe wingmust
bedone at the same time forproper fittingW 23's are
fixedto the wingwhileW 24 and W 27 are fixedto the
fuselage Smooth jointswithDap
6

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plus50centsto TopFlite
©TopFlite Models,Inc.1981150308'