Stevens AeroModel G-480, Assembly Instructions Manual

Page 1: ... 2004 Stevens AeroModel Page 1 of 33 G 480 V1 11 Span 45 Length 44 Area 400 Sq Weight 22 28oz ...

Page 2: ... powerful system is not recommended Similar to full scale and giant scale models this high performance model requires careful throttle management When tracking through a down line it is mandatory to govern the use of throttle slowing the models descent to avoid over stressing the airframe ...

Page 3: ...onal aft servo pocket location Glue this optional part in position as illustrated when you assembly your fuselage sides This option eliminates the pull pull assembly for the elevator and allows for greater CG adjustment with heavier motor systems A A F8 B B Requires 12 Extension B B F17 Optional ...

Page 4: ...wheel 3 Dubro Micro Pull Pull Assembly DUB846 4 Dubro Mini E Z Connectors DUB845 5 1 2 Roll s of Solarfilm So Lite Nelson Lite or Ultracote Lite Iron on Film Covering Suggested Radio Gear 1 4 5 Channel Transmitter 4ch using Y harness for ailerons 2 4 Sub Micro Servos Hitec HS 55 or equivalent 3 1 6 Y Servo Extension 4 2 12 Servo Extension 5 1 Micro Receiver 6 1 25A ESC Castle Phoenix 25 recommende...

Page 5: ...ork Tape plans to work table Cover with clear painters drop clot wax paper or plastic wrap Join all joints with Thin CA unless otherwise specified DO NOT REMOVE THE PARTS FROM THE BALSA SHEETS UNTIL REQUIRED In fact while the balsa parts are still retained in the sheets now is a good time to run a few good swipes with a sanding block over both sides of the sheet to remove any resin residue from th...

Page 6: ...halve and allow to dry Once dry use a small amount of 5 minute epoxy to create a fillet between the wood and the metal tube 3 Sand all surfaces with fine grit sand paper rounding leading edge pieces while leaving trailing edge parts square in preparation for your preferred hinging method Centered CA Hinging is Recommended Fuselage Fuselage components are exceptionally brittle until the entire asse...

Page 7: ...y the assembled part FB1 into position spanning the fuselage sides and F2 Tack glue fuselage box together forward of former F2 4 Pull the fuselage sides together at the aft end and secure with a piece of tape Assemble cross braces into part FB2 Key the assembled part FB2 and F3 into position spanning the fuselage sides Gently draw fuselage sides together fitting the notches in the fuselage top dec...

Page 8: ...ry tray BT1 Secure BT1 to F2 F3 F4a and F4b with CA glue make a good strong joint here use two to three applications of thin CA or one application of thick CA allowing time to cure in between applications 6 Fit Servo rail fuselage doubler part SR1 inside fuselage to double FT1 servo pocket 7 Friction Fit former F5A to 1 8 fuselage gussets F5B to create former F5 ...

Page 9: ... spanning F5 and the fuselage sides FB3 10 Sand a slight bevel along the edges of part F8 and key to fuselage sides and FB3 Re secure this area with tape 11 Support fuselage assembly upright on a flat surface and tack glue F5 FB3 and F8 into position Verify that the fuselage tail section is square to the building board and run thin CA along all inside surfaces Work slowly and make strong joints ...

Page 10: ...13 Key part FT2 to fuselage sides spanning F7 and F8 Fit part FT3 into position aligning with the exposed tab of F8 Run thin CA along inside surfaces 14 Key FT4 into position secure with thin CA 15 Key F14 and F15 turtle deck spine into position Part F15 spans FT4 F7 F6 and F14 Secure parts with thin CA ...

Page 11: ...with former F14 18 Key parts F11 and F13 to fuselage top decking Note orientation of F13 instrument panel and decide if you want it hidden or exposed Key center spine F12 spanning F11 and F13 Fill in remainder of slots with pre cut stringer stock Once satisfied with fit glue the assembly together by running thin CA along all inside surfaces Note the servo tray included with the beta kit Stringers ...

Page 12: ...tate the fit We want a good snug fit to the fuselage firewall Once satisfied with the glue the motor mount in place and flow thin CA liberally into all motor mount joints 21 VERY IMPORTANT Special Instructions for the AXI 2808 X Series motors Locate the 1 32 ply doubler MM1b using 5 minute epoxy or wood glue laminate this doubler to the face of MM1a Spread a thin epoxy fillet along the inside join...

Page 13: ...on the full size plan sheet for more details A A B B 0 1250 1 0000 Upper Guide Tube Left or Right only F5 F14 F6 F7 Lower Guide Tube Left and Right Elevator Pull Pull Cable F6 Servo Servo FB3 Elevator Pull Pull Cable Rudder Pull Pull Cable Rudder Pull Pull Cable Lower Pull Pull Exit Bottom of Fuselage Optional External Rudder Servo Mount Location Pull Pull to rudder runs external to fuse Assists w...

Page 14: ...ssembly will be pulled together straight and true 1 Begin wing construction by locating and joining together with thin CA parts S1A and S1B to create the main spar 2 Locate and CA together parts S3A S3B and S3C to create S3 upper spar cap strip do the same for S2A S2B and S2C to create lower spar cap strip S2 3 Locate ribs R1 3 32 and R2 1 16 and CA the cross bracing in place in the notches provid...

Page 15: ...f the wing 6 Locate leading edge jig LE3 and key to ribs R1 and R6 Make sure that LE3 is properly nested into the notches in R1 and R6 then tack glue LE3 to R1 and R6 leaving the rest of the structure un glued Note To assist wit the fit of LE1 to the ribs it often helps to lightly bevel the interlocking notches on LE3 using a very fine grit sand paper 7 Nest the wing center brace part W1 in betwee...

Page 16: ...be tricky to work into position and it is easy to make two rights or lefts For this reason inspect the fit of the parts to each other and test fit the parts individually to the wing Assemble the servo pockets as illustrated below For this step you will need parts W6 W7 and the 1 16 ply parts W8 Once the servo pockets have been dry fit together test the fit to the wing spar and rib R3 Work the asse...

Page 17: ...Tack glue the center trailing edge component to R1 and R2 where these parts intersect 12 Assemble the landing gear block Locate parts LG1 LG6 and friction fit together as indicated in the photo below 13 Key the center landing gear block to the wing between ribs R1 and the main spar Align flush with R1 and the main spar Tack glue into position ...

Page 18: ... rib bays make sure to adequately support the spar as you work the strip into position Next lay the entire wing assembly over your flat building surface inverted Add some light weights to hold the wing flat against the building board Working slowly in between ribs gently press the assembly against the flat surface and wick CA into the upper in this case bottom as the wing is inverted cap strip to ...

Page 19: ...ading edge jig LE3 Note It may help to slightly bevel the tabs on LE3 before fitting LE4 also LE4 is designed to fit in one direction pay close attention to the notching 19 Stand wing up along its leading edge supported over your flat work surface Hold LE3 firmly against LE 4 and wick thin CA along joints between LE3 and LE4 surfaces ...

Page 20: ...rt W3 center brace in between ribs R1 aligned with the centerline of parts TE1 22 Again invert and weight the over your flat building surface Fit the pre cut turbulator stock to the wing and secure with thin CA If for some reason your wing does not come out straight and true you may simply leave the wing inverted on your flat work surface weighted down mist liberally with glass cleaner solution an...

Page 21: ...4 Install wing center section stiffeners W2 flush with the upper wing surface as illustrated below 25 Sand leading edge round to match shape of airfoil 26 Test fit the wing to the Fuselage and inspect for proper fit Sand trailing edge of wing to fit fuselage wing saddle ...

Page 22: ...CA 2 Key parts A2 A3 A2 to aileron trailing edge A4 to create aileron control horn pocket see rolled plans and illustration for more details Lay assembly on a flat surface and secure with thin CA 3 Key parts A5 and A5 together perpendicular to one another the serrated notching should assist with the assembly and fit Test fit aileron rib and trailing edge assembly to parts A5 A6 leading edge tack g...

Page 23: ... wire this wire can be difficult to work into shape using ordinary needle nose pliers For the task of shaping the gear legs we recommend the use of a small hobby vise 3 Install gear wire into channels in gear spade and laminate second part LG8 to top of spade capturing gear legs within Next run thin CA into spade by allowing it to wick in along the gear legs where they enter the spade Sand exterio...

Page 24: ...following wheel pant part up in the following order UP FROM THE BUILDING BOARD Make two stacks of WP1 WP2a WP2a WP2b and WP2b stack them in front of you as illustrated Now grab one stack and laminate each part to the next complete for the second stack 2 Build Stack B Stack up again working up from the building board parts WP4 and WP3 Make two stacks oriented as illustrated Work with one stack at a...

Page 25: ...r legs retaining the wheels You may find it helpful to use part WP6 to shim the wheels within the pants this is not required The main gear wire nests into the channel and is retained by part WP5A and the eight 0x3 16 screws located in the small parts bag Tail Wheel Use the full size rolled plan sheet marked FUSELAGE as a reference for completing the tail wheel assembly 1 Using the plan sheet as a ...

Page 26: ...anopy Cowl 1 Trim canopy along scribe line on the molded part 2 Trim cowl along scribe line on the molded part Trim away inside recessed area of cowl to promote cooling of the motor 3 Test fit both to fuselage the fit of the cowl is very precise some light sanding of the fuselage may be required to achieve a perfect fit Hint Painting the Cowl Lay up multiple thin coats of paint allowing ample time...

Page 27: ...A secure with thin CA Test fit wing to fuselage Once satisfied remove the wing and harden the fuselage reception holes for the wing locating dowels with thin CA Fit CA hinges to ailerons and wing secure with thin CA Slip the 1 32 ply aileron control horn into the appropriate position on the aileron see plan sheet for details Secure with a dab of thin CA Install tailskid tail wheel assembly bracket...

Page 28: ...e you are comfortable with the flight envelope of this model Tip Balance model upside down Prior to heading off to the field sight along wings and tail surfaced and remove warps if found Set control surface throws Suggested initial rates Elevator 1 2 Ailerons 1 2 Rudder 1 Choose a calm day for your maiden trim flight Slowly advance throttle within a few feet you will be airborne The G Ride slows d...

Page 29: ... 2004 Stevens AeroModel Page 33 of 33 THIS PAGE HAS BEEN PROVIDED TO SCHEME A COLOR SCHEME M PJ45DEG H o r iz o n ta l S ta b E le v a to r W 3 ...