Zippkits JAE GAS OutriggerV2 Instruction Manual

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ZIPPMANUFACTURING
JAEGASOutriggerV2
AZippkits R/CBoat
Building Instructions
2012ZippManufacturing
www.zippkits.com
TollFree (866)922-ZIPP

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The JAEoutriggerwasdesignedanddevelopedasaresultofajoint venturebetweenIMPBA
Hall ofFamememberRodGeraghty, alongwithDavidHall, RonZakerJr.&MartinTruexJr.
The maindifferencebetweenthishull andall theothersistheuseof sharpedgesonthe bottom
ofthesponsonsandtub,asopposedtocurved surfaces.Thishelpsbreakanysurfacetension
ofthewaterandmakesforafasterboat.
Thisdesignapproachhasbeenbuilt, developedand testedagreatdeal.
Thiskit representsthe latestgasolineversion asof March2012. The changeswemadewere
many,yettheboat still looksalmost exactlythesame. Most of the changesweremadesothat
theboatwaseasiertobuild,easiertosetup,handled better,wasfasterandeasiertorepair.
Manyofthechangeswerearesultof ourexperience,andsomeweretheresult of customer
request.
All inall,thiskit istheverybest wecanmakeit, thanks toyou,ourcustomer.
The kitisnothardtoassemble,asall of the hardstuff hasbeen doneforyou.
Thatisnoexcusetodo apoorjobwithassembly. The betteryoubuildthisboat,thebetteritwill
run.Often thedifferencebetweenan excellent buildingjobandapooroneisasimplesanding
block.
Anoteaboutoverhangs:
Thisboat isdesignedtoshearwaterandpreventanycapillaryactionof water. Todothisthe
tub, skiandsponsonshaverearoverhangs. Theseshearthewateroff and mustbeleftinplace
andnot rounded inanyway.
Takethetimetoreadthisentiremanual, sothatyou arefamiliarwithall thebuilding
stepsand theirproperorder.Takeyourtime;make sureyou understand everything
beforeyou do itand you willberewardedwithanimpressiverunning hull…
Thiskit isnot atoy. Although R/Cboatingisafunandrewardinghobby,it canbedangerous
ifnot donewithcommonsenseand safetyinmind. Justaboutanyoneshouldbeableto
buildthiskit, butit shouldnot beoperated bychildren without closeadult supervision.
Themanufacturerassumesno liabilityfordamagesorotherloss intheuse ofthisproduct,as
wehavenocontrol overtheconstructionorend useofthisproduct.

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Toolsandsuppliesneededtobuild
§Sandingblockswith80 and150 gritpaper
§220,400and 600 gritpaper
§Drill with bits
§Square
§Flatfile
§FLATWorkbench
§1/2ounce MediumCAglueandaccelerator
§Goodquality30 minuteepoxy
§Epoxyfinishingresin
§Springclamps,paperclamps,cclamps,etc.
§Weightsorbricks
§RazorbladeorX-Actoknife
§Maskingtape
§Waxedpaper
§Woodfiller
§Primer
§Paint

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Additionalitemsneededtocomplete
§23-36ccwater cooledGasolineenginewith 5inchmounts
§.250Colletfor engine(Zipp 3446forZenoah,Sikk,RCMK)
§.25024inchcablew/welded1/4stubshaft(Zipp3444)
§Headertofitengine(Zipp2000for sideexhaust)
§Exhaustflange (Zipp 2008)
§Tunedpipe(Zipp2011)
§2channelsurfaceradiowith 2servos (1quarter scaleservo)
§Rudder pushrod(4-40Size)(Zipp3463)
§4-40ball link(Zipp3457)
§4-40solder clevis(Zipp3455)
§Throttlepushrod(2-56size)(Zipp3462)
§2-56nylonclevis(Zipp 3459)
§3pushrodseals(Zipp3404)
§12-16ounceFuelTankor IVbag(Zipp3506IVBag)
§.250strut (Zipp3496)
§.250drivedog(Zipp3442)
§Zipp 678or ABC 2818/2prop(startingpoint)
§Propnuts(Zipp3450)
§Cablegrease
§Rudder(Zipp3414)
§36inchlengthof5/16brass tubing(Zipp3452)
§36inchlengthof5/32brass tubing(Zipp3510)
All of therequiredhardwareandaccessoriesareavailableinasingleUltimate
HardwarepackageasZipp3605-U.
Thispackagecontainseverythingexcept the bare engineandradio.

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Let’sidentifythepartssothat wecaneasilyfindthemwhen needed. Markthepartsthatare
insideotherparts.
/6 plywood parts:
Foam parts

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/8 plywood parts
¼ plywood parts

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Miscellaneous parts
Doaninventoryofall the parts, tobe surethateverythingisthere. Ifanything ismissing
ordamaged, contactusassoonaspossible, sothat wecangetreplacementstoyou quickly.
Tub Jig
Werecommendthatyoumakeajigforthetub.
Thiscanbe assimpleastwostraight piecesof ½to¾inchthick wood.
It can be aselaborateas1/8by2inchaluminumanglewithadjustment slotsfordifferenttub
widths.
Eitherway,youneed somethingtoclampthetub sidesto.
Everycriticalcomponenton thishull dependsonastraight,squaretub.
Dowhateverittakestogetitdone correctly.

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Tub sidesmarkedbeforeassembly.
Ledgeforradioboxlidframe.
Tub sideshownwithboomtubeforalignment.
Tub
Let’sbuildthe tub.
The tubsidesarelaminatedfrom2piecesof1/8
ply, sotakeyourtimeandmakesureyou
understandthetubassemblybeforeyouglue
anything.
First, markthe insidesoftheinnertubrightand
left.
Makethesemarks inthefrontportionof the
sides,whereit won’tbeseenlater.
The outersidesarethesame,exceptthatthere
areno lightening orbulkheadholes.
Noticethelittle“ledge”attherearof the inner
sides.Thisisfortheradioboxlidframe.
Useafiletotouchupthe insidecornersonthe
tubsides, tosquareoff thetinyradiusleftbythe
cuttingbit.
Glue theinnersidestothe outers, makingsure
that youhavea RIGHT and a LEFT side(they
aremirrorimagesofeachother).
Usethe aluminumboomtubestoensureperfect
alignmentof theinnerand outersides.
Trynottogetanyglue inthe slotsforthe
bulkheads.
Besurethat therearof thesidesareflushat the
bottom,andhavethe1/16gapatthetop.
Besuretoscrapeanyexcess epoxy awayfrom
thiscorner,asthelidframewill begluedhere
later.
Check tomakesurethatthesideshavenot
slippedoutof alignment.
Allowtocure.
Check thefitof thebulkheadsintheright tub
side.

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Tub sidesgluedtobulkheads.
Forwardtubsideshanging pastendofjig.
Tub withaftbottominplace.
Makesurethat therear3bulkheadshavethe2
littleholesonthe right.
Theseareforthe brass coolingwatertubes
installedlater.
Onceyouarehappywiththefitof thebulkheads
inthetubsides,gluetheminwithCAorepoxy.
Usethe squareprovidedinthekittoensureeach
bulkheadisperfectlysquare.
When cured,flipthetuboverandlightlysandthe
bottom.
Nowisthe timetouseyourtubjig. If youdon’t
havethe abilitytomakeanaluminumjig,usea
pairof straight, thick woodensticks. Leavethese
clampedtothesideswhilegluingthe aftbottom
inplace.
Putalayerofwaxedpaperoverthejig.
Putthetubaft bottominthejigand setthetub
ontoit.
Fullyclampthetubsidestothejig.
Check all around tomakesurethatthetubfits
properlyonthebottomsheet.
Removethetubfromthejiginpreparation for
gluing.
Using epoxy,gluethetubaftbottominplace.
Makesurethat thebottomextendstothefront
bulkhead.It shouldcoverthe full 1/4inch
bulkhead.
Leavetheoverhangat therearof thetub. Donot
sandthisoff.
Ifyouuseanythingotherthan aluminumangle,
makesurethat thebottomsheetdoesn’tmove
sidewayswhileit cures.
Thiscanoccurif youuseangleiron,orsome
otheranglethat doesn’thaveasharpangle.
It maybeagoodideatodrawalineonthe
bottom,alongtheinsideof the tub, tobe surethe
bottomsheethasnot moved.

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Sub nosegluedinplace.
Transomdoublerclampedinplace.
Aftbottomsheetsandedandreadyforfwdbottom.
Glue thetubsubnosetothe veryfrontof the tub.
Thissupportsthenoseforsheeting,andprovides
asolidbaseforthetubnoseblock.
Thereshouldbeaslightoverhang onall sidesso
that the subnosecanbe sandedtoshapelater.
Glue inthetransomdoublerwithepoxy.
Makesurethat it fitsflatagainst the transom,and
that it sitsfirmlyonthe tubbottom.
Clampuntil cured.
When cured, removethe tubfromthejigand flip
it over.
Puttheupsidedowntubback inthejig.
Sandthefrontedgeof the bottomsheetsothat it
matchestheangleof the forwardbottom.

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Fwdbottominplace.Noterearoverhang.
ThisiswhatmakesaJAEaJAE…Sponsonsaresimilar.
Bambooskewersgluedinplace.
Glue theforwardbottomsheet inplace.
The forwardsheet shouldoverhang ontherear.
Seedrawing.
When cured,sand thebottomsheetsflushwith
thetubsidesandfront. Donot sandoff therear
overhang.
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Drill two1/8inchholesthroughthetubsides, into
thetransom.Maketheseabout¾inchdeep.
Cut 4piecesof bambooskewerabout aninch
long.
Putadropof glue inthehole,and hammerthe
skewerineachholeuntil it bottomsout. Allowto
cure.
Cut theskewerwithsidecuttersandsandflush.

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Sandedflush.
Radioboxlidsupportgluedinplacebehindbulkhead3.
Radioboxlidsupportinplace.
The transomisnowpermanentlyattached,
without theneedforanyadditionalreinforcement.
Glue inthelidframesupport. Thisgetsattached
totherearofbulkhead3,andisflushwiththe
lowerportionof thesides.
Besurethat thelidframesupportisflushwiththe
lower(inside)edge.
The 1/16 radioboxlidframewill goherelater.

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Engineinplaceon scrapsofwoodasspacers.
Tracingaroundmounts.
Using awashertodrawholes fordrilling.
Engine
Install yourengine onitsmounts,then setthe
engineand mount inplace.
Usesomescrapsofplywood undertheengineto
spaceoff thefloor.
Useabout1/8inchinthe rearand3/8inchinthe
front(pull startend).
Mount the enginesothat the sparkplugisabout
19-1/2to20inchesforwardof thetransom.
Useapieceof1/4brass tubeordrill bittomake
surethat theengineisalignedwiththeholesin
therearbulkheadand floor.
Putthe¼inchtube orbitinthecolletandsnugit
up byhand.
Ifyouwanttobepreciseabout theshafttube
location,youcan slipapieceof9/32 brasstubing
overyour¼.
Thiswill then beaniceslipfit toyour5/16shaft
tube.
It shouldlineupperfectly.Ifnot, put scrapwood
spacersunderthe enginetogetit tothecorrect
heightandangle.
Onceyouarehappywiththeengineplacement,
drawaroundasmuchof therubberisolatorsas
you can. Removetheengineanduseaflat
washerabout thesizeof therubberisolatorsto
drawacenterhole.

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Drilling holesformounts.
Rightangledrillishandy.
Shafttubealignedproperly.
Useacenterpunchornail tomarkthe centerfor
yourhole.
Drill thishole¼inch,andmount theengine.
Withtheengineinplace, wecan moveontothe
shaft tube.
Slide your5/16shafttubeinuntil itisabout ¼
inchfromthe collet.
Makeasmall markwhereyour5/16 tube goes
throughthe bulkhead.
Makeanothermarkabout6inchespasttheback
oftheboat.
Cut thebrasstubehere.
The 5/16 inchbrasstubingneedstobe
annealed.
Thiswill makeit easy tobendbyhand, without
kinks.
Onlyannealthebrass tubefromthemarkyou
maderearward.Wedon’t wanttoannealthe
forwardportionthatsticks throughthebulkhead.

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Epoxywithfillerinplace.
Besuretopack theepoxyaround thetube.
Tapeontubbottom,aroundshafttube.
Toannealthetube, simplyheat it withany
propanetorch,until it changescolor.
You will seethe brasscolorchange toasortof
blue. It onlytakesacoupleof seconds,sowatch
forit.
When yousee thetubing changecolor, movethe
flameslowlydownthetubeuntil thewholething
isdone.
Putascrewdriverinoneend of thetubingtohold
it whileyouheatit.
Trynottoannealthelast inchorso.
You caneitherset the hot tubeon aheatproof
surface(concretewill do),oryoucan quenchit
withwateruntil cold.
When cool,useaScotchBritepadorcoarse
sandpapertoscuff thebrass tube.
Puttheshaft tubethroughthe holeinthetub
bottom,andthroughbulkhead 3.
Puttheendthatyoudidn’t annealtowardsthe
engine.
The tube shouldstart¼inchbehindtheengine,
andcontinueabout6inchesbehindthetransom.
Ifthe tube fitsokaywecanepoxyit inplace.If
not, sandthe opening(s)until itdoes.
Glue theshaft tubeinplacewithepoxy andfiller
(tothicken).
Besuretosandtheshaft tubewheretheepoxy
will be.
Topreventepoxy fromrunningoutthe bottomof
theslot, usetapetomakea“dam” onthebottom
ofthetub.
Allowtocurefullybeforetouchinganything.

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5/32brasswatertubes installed.
Frontendoftubes.
Rearedgeofskisandedtoshape.
Water lines
Cut your5/32brass tubingsothatyouhavetwo
pieces,each16incheslong.
Deburr theends(insideandout)andputthemin
placeinthepre-drilled holesinthebulkheads.
Leaveabout ¾inchstickingoutthetransom.
Putadropof epoxyaround eachtube whereit
goesthrougheachbulkhead. Dobothsidesof
thebulkheadsforaleakfreeinstallation.
Ski
Assemblethe3partsof the skiusing epoxy or
CA.
Letthebottomoverhang past thesidesabout1/8
inchatthereartoallowforsanding.
Glue theski bottomontothesides. Leave
about1/8inchofbottombehindtheskisides.
Clamportape thisassemblyuntil cured.
Besurethat theskisidesare90degreestothe
bottom.WeusedmediumCAandacceleratorfor
this.
Sandasharpbevelontherearoftheskibottom
sheet, sothat it matchestheskisides. Sandthe
frontof theskibottomsothat ittaperstonothing
Donot gluetheskitothetubyet.

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Shafttubebentforskiclearance.
Skiinplace.
Strutmountingholesmarked.
Bendtheshafttubesothattheskifitsoverit.
The tube shouldtouchthe skiwhen theskiisin
placeonthetub,
Tapethe skiinplaceovertheshafttube.We
wanttheskitositflat onthetub,and thestrut to
sit onthe bottomof theskiattherear.
Strut
Makeapencil line inthecenterof thetransom
andmountthestrutbracketflushwiththetopof
thetransom.
Slide thestrutontotheshafttubeandbolt in
place.

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Strutinposition.
Strutsitting onrearofski.
Rudderinposition on bottomoftransom.
Boltthestrut inthetub, touchingtheski. The
shaft tubeshouldgoall thewaythroughtheZipp
strut. Slightlybendtheshafttubesothatthestrut
will slide onandbolt squarelytothetransom.
Markthe tubewhereit exitsthe strut.
Removethestrutandcuttheshafttubeat your
mark. Cleananddeburr thiscut inside and out.
Removetheski.
Rudder
Bolttherudderinplace. Thisshouldbe asfarto
the left aspossibleand sitting on thebottom
sheetoverhang (aslowaspossible).
Makeamarkonthe transomwheretherudder
pushrodwill exit.
Sight thisfrombehindtheboat.
Drill a¼inchhole,onyourmark.

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Boomtubedoublersinplace.
Rudderservomountparts.All are¼ply.
Servomountassembled.
BoomtubeDoublers
The boomtubedoublersare¼inchplyandgive
addedsupporttothealuminumboomtubes.
Usethe boomtubestolocatetheseandepoxy in
place. Useclampsandremovethealuminum
boomtubesbeforetheepoxycures.
Wipeoff anyepoxyonthe tubes.
RudderServo
Assembletherudderservomount. Thisismade
fromtheservomountbasepartsand thestrap.
Thismountwill fit “quarterscale”sizedservos.
The rudderservomountbaseisassembledfrom
3pieces.
Glue the¼inchspacertothebottomsideofone
ofthemounthalves.Besurethatthe spaceris
perfectlyaligned.
Glue theotherhalftothespacer.
Weused mediumCAforthis.
Putthisassemblyon thebenchtobesurethatit
sitsflat.
Clampuntil cured.
Check theheightofyourservo. Themount
shouldbeatinybit shorterthanyourservo.
Ifnecessary,sand thetopof themountsslightly
until theservoisabout1/32inchtaller.
Setthe¼plystrapinplaceand drill pilotholes
witha1/16bit.
Donotomit theseortheplywill split.
Puttheservoinplaceand clampitdownwiththe
strap and4servoscrews.
Noticethat thescrewsonlyneedtobe snugto
holdtheservosecurelyinplace.

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Quarterscaleservoinplace onmount.
Rudderservoandpushrod inplace.
4-40solderclevisatservoend.
Thismountputstheservoarm inthecorrect
position forastraight pushrodruntotherudder.
Wewill usetheinnermost servoarm hole.
Threada4-40 ball linkontoa4/40pushrod.
Slipthisintotheholeinthetransomand
bulkheadandattachit tothe rudderwitha4-40
screwand nut.
Sandthebottomof theservomountsothat itis
flat.
Puttheservo/mountassemblyinpositionabout1
inchforwardof therearbulkhead.
Markthe pushrodwheretheservooutputshaft
is.
Removethepushrod.
Cut thepushrodandsolderaclevisinplaceso
that itspiniswherethemarkwas.
Putthepushrodback inplace.
Putaservoarm ontheservosothatit isfacing
straightdown.
Popthe clevisintotheinnermost holeinthe
servoarm and movetheservo/mountassembly
arounduntil the pushrodisnottouchingthe hole
sidesandtherudderusstraight.
Useepoxytoglue themount inplace,again
makingsurethattherudderisstraight.
Don’tget anyglueontheservoorwire.
Allowtocure.