GREAT PLANES Ultimate 40, Instruction Manual

Page 1: ...he use by the user of the final user assembled product By the act of using the user assembled product the user accepts all resulting liability If the buyer is not prepared to accept the liability asso...

Page 2: ...e 37 Suggested Covering Sequence 38 Painting 38 Final Hookups and Checks 38 Install the Hinges 38 Install the Hardware 39 Attach the Canopy 39 Radio Installation 40 Install the Rudder Elevator and Thr...

Page 3: ...g 3 Use an R C radio system that is in first class condition and a correctly sized engine and components fuel tank wheels etc throughout your building process 4 You must properly install all R C and o...

Page 4: ...balsa filler such as Hobbico HobbyLite Hobbico HCAR3400 D 1 4 20 Tap and Drill GPMR8105 D IsopropyI rubbing alcohol 70 D White body putty Squadron SQUR1500 D Ballpoint pen D 90 Building square HCAR048...

Page 5: ...h the plan and the parts list included with this kit Using a felt tip or ballpoint pen lightly write the part name or size on each piece to avoid confusion later Use the die cut patterns shown on page...

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Page 8: ...as a guide to make sure the stab TE is straight as you glue it in position Note Refrain from using excessive accelerator Hours after it s sprayed on residual accelerator can prematurely and unexpected...

Page 9: ...e plans or a straightedge as a guide to make sure the rudder LE is straight as you glue it in position D 1 Pin the die cut 1 4 balsa fin bottom S 2 over the fin plan Cut the fin outer frame from a 1 4...

Page 10: ...flat surface Mark a test line on the trailing edge of the stab B Flip the stab over and mark another line in the same location as the first If you see only one line then it is on center Proceed and m...

Page 11: ...cess deep enough for the torque rod D 2 Drill 3 32 pilot hole into the elevator LE on the centerline at the torque rod marks As you drill the holes keep the drill aligned with the top and bottom surfa...

Page 12: ...th a hobby knife as shown in the sketch above TWO WARPED SPARS INSTALLED THIS WAY WILL RESULT IN A WARPED WING D 2 Match sets of 1 4 x 3 8 x 24 balsa wing spars so any warps will counteract each other...

Page 13: ...in spar and the joiner ends should be flush with the forward edge of the main spar Make sure the top of the joiner is flush with the bottom of the slots for the top main spar D 12 Use 6 minute epoxy t...

Page 14: ...ge of the sheet should cover the forward half of the main spar The root end should cover one R 4 and R 5 rib D 17 From a 1 16 x 3 x 24 balsa sheet cut and glue shear webs perpendicular to the aft edge...

Page 15: ...g flush with the side of tip rib R 1 D 8 Use a 1 16 x 3 x 30 balsa sheet to make the center sheeting between the LE sheet and the TE sheet Save the remaining sheeting for the bottom center sheeting Th...

Page 16: ...sheeting flush with the side of tip rib R 1 D 8 Make the wing tips from a 1 8 x 3 x 18 balsa sheet Hold the sheet against tip rib R 1 and draw an outline of the rib Cut and glue the wing tips to tip r...

Page 17: ...ervo tray perpendicular to the tray Glue the tray doublers to the bottom of the aileron servo tray D 10 Glue the servo tray to ribs R 6 D D 1 Trim one end of the 1 1 4 x 24 balsa aileron to the same a...

Page 18: ...red drill 5 32 holes at the four engine mount punch marks Drill a 3 16 hole for the throttle pushrod at the appropriate location Drill two 1 4 fuel line holes in the center of the engine mount holes D...

Page 19: ...Drill 5 16 holes at the punch marks on the upper fuse sides D 3 Caution Make sure to glue the right side doublers to the right side fuse Position the fuse sides next to each other as shown Glue the d...

Page 20: ...e formers perpendicular to your building board use thin CA to glue formers F 12 thru F 8A B to the fuse sides top deck and aft fuse bottom The fuse sides should be perpendicular to the building board...

Page 21: ...r plate Insert 6 32 x 1 2 cap head screws with 6 washers through the landing gear and landing gear plate Thread a 6 32 blind nut on the cap head screw from the back side of the landing gear plate Scre...

Page 22: ...mer F 11 and cross each other before passing through former F 10 Approximately 7 of the guide tube should protrude past F 10 D 1 With the fuselage upside down in a foam cradle fit the wing in the wing...

Page 23: ...nd the high side of the stab plate until the stab is aligned Check that the stab tips measure the same distance from the center of the firewall Draw alignment marks on the bottom of the stab Remove th...

Page 24: ...p of the fuse and stab Next glue it to the formers and backrest Finally glue it to the stringers and the fin D 6 Repeat the process to install the turtledeck sheet on the other side of the fuselage D...

Page 25: ...and former F 5 The center lingitudinal brace is die cut as two pieces and will need to be glued together Glue the die cut 1 8 balsa former F 6 over the longitudinal braces D 11 Remove the elevator joi...

Page 26: ...die cut 1 8 plywood tank hatch lip on top of the offset flush with the front of the off set D 7 Make two 13 1 2 long top deck sheets from the 3 32 x 3 x 36 balsa sheet Fit the edge of one sheet agains...

Page 27: ...the die cut 1 8 plywood ribs R 10 and R 11 sandwiched between ribs R 8 Glue the die cut 1 8 ribs R 12 and R 13 sandwiched between the ribs R 9 D 1 Pin the die cut 3 32 balsa ribs R 1 and R 7 in posit...

Page 28: ...with the bottom of the slots for the top main spar Allow the epoxy to cure before proceeding with the next step D 10 Trim the leftover LE to fit between the installed LE When satisfied with the fit gl...

Page 29: ...hine screw from the bottom up through the top of the forward cabane and a 6 32 x 1 1 2 machine screw in the aft cabane Secure the screws to the cabane with 6 32 nuts D 22 Use masking tape to hold the...

Page 30: ...d should cover to the center of rib R 10 D 1 Mount the top wing on the fuse along with the struts D 3 Position the front of the LE sheet against the LE and glue it in position with thin CA D 4 Careful...

Page 31: ...f the cap strip on the R 1 tip rib should be flush with the side of the rib On the double rib for the strut glue tow cap strips D 5 Drill a 5 32 hole through the top center sheeting using the hole thr...

Page 32: ...use and at the wing tips If the distance at the tips is larger reduce the length of the struts a little at a time until the wings are parallel D 1 Sand the TE sheet and TE flush D 2 Mark the centerlin...

Page 33: ...g Cut the hinge slots and without using glue test fit the aileron to the wing D D 6 Remove the aileron from the wing Mark the bevel to lines and trim the LE of the aileron to a V as shown on the plan...

Page 34: ...em together the seam will be as small and straight as possible Notice that the rear of the pant halves do not overlap Roughen all the areas that are to be glued including the indentation on the inside...

Page 35: ...ely 1 8 D 11 Enlarge the axle notch to 11 64 in the landing gear Temporarily mount the wheel pant to the landing gear with another 8 32 nut Note When you reinstall the wheel after the wheel pant has b...

Page 36: ...d remove the tape and make sure you have thoroughly glued the two pieces together by inspecting the glue joints and adding thin CA if necessary D 6 Drill a 3 32 hole through the cowl and fuse at each...

Page 37: ...from the model with compressed air or a vacuum with a brush and a tack cloth Do not confuse this procedure with checking the C G that will be discussed later in the manual Now that the model is nearl...

Page 38: ...f the canopy that is not to be painted If you are not sure that the paint is compatible with the clear canopy test the paint on a leftover piece of canopy material For painting the pilot we have disco...

Page 39: ...Install the rudder with its hinges Repeat the gluing technique described previously and allow the epoxy to cure D 1 Assemble the fuel tank according to the manufacturer s instructions Remove the fuel...

Page 40: ...the servo tray with the servos aft D 4 Plug the servos into the receiver Wrap the receiver in foam padding and rubber band it in the servo tray Insert the servo tray under the outer pushrod tubes and...

Page 41: ...e control horns With the radio switched on and the servos centered position the control surfaces to neutral Mark the pushrod where it crosses the mounting holes in the servo arm D 11 Install a silicon...

Page 42: ...aslinks as described before D D 15 Attach both wings to the fuse Position the small control horns on the TE of the ailerons in line with the struts With the control horn base flush with the TE of the...

Page 43: ...n smoothest most proportional movement Note We found that some mixing of the elevator and aileron with the rudder will make flying knife edges easier D 1 Mount both wings on the fuselage and block up...

Page 44: ...ops it is nose heavy and you must add weight to the tail to balance the model If possible first attempt to balance the model by changing the position of the receiver battery If you are unable to obtai...

Page 45: ...eady know about AMA chartered flying fields and other safe places to fly If for some reason you are a relatively inexperienced modeler and have not been informed we strongly suggest that the best plac...

Page 46: ...ve right of way to and avoid flying in the proximity of full scale aircraft Where necessary an observer shall be used to supervise flying to avoid having models fly in the proximity of full scale airc...

Page 47: ...little slower and allow yourself time to think and react Add and practice one maneuver at a time learning how the Ultimate 40 behaves in each For smooth flying and normal maneuvers use the low rate s...

Page 48: ...TWOVIEW Photocopy this drawing and use the copies to design your trim scheme PRINTED IN USA 3005155...