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GREATPLANES R-Craft Manual

1. X dos a dE dE 47 FLYING 22040440000 RR au ee 47 47 FE WOU Ged iss 47 47 2 VIEW DRAWING Back Cover PROTECT YOUR MODEL YOURSELF amp OTHERS FOLLOW THESE IMPORTANT SAFETY PRECAUTIONS Your T Craft 20 is not a toy but rather a sophisticated working model that functions very much like an actual airplane Because of its realistic performance the T Craft 20 if not assembled and operated correctly could possibly cause injury to yourself or spectators and damage property To make your R C modeling experience totally enjoyable we recommend that you get experienced knowledgeable help with assembly and during your first flights You ll learn faster and avoid risking your model before you re truly ready to solo Your local hobby shop has information about flying clubs in your area whose membership includes qualified instructors You can also contact the national Academy of Model Aeronautics AMA which has more than 2 500 chartered clubs across the country Through any one of them instructor training programs and insured newcomer training are available Contact the AMA at the address or toll free phone number below 1 b j SINCE 1936 Academy of Model Aeronautics 5151 East Memorial Drive Muncie IN 47302 9252 Tele 800 435 9262 Fax 765 741 0057 or via the Internet
2. Building Supplies These are the building supplies that are required We recommended Great Planes Pro CA and Epoxy glue L 1 oz Thin Pro GPMR6002 L1 1 oz Medium Pro CA GPMR6008 L1 6 Minute Pro Epoxy GPMR6045 1 30 Minute Pro Epoxy GPMR6047 I Thread locking compound GPMR6060 Balsa filler HCAR3401 L Canopy Glue Plan protector GPMR6167 L1 Isopropyl rubbing alcohol 70 L Paper towels L Sanding block and sandpaper coarse medium fine L1 Hobby knife 0105 L1 11 blades HCARO21 1 a Single edge razor blades 0212 1 Razor saw 1 Razor plane MASR1510 LI Electric drill LJ Drill bits 1 16 3 82 5 32 3 16 13 64 7 32 1 4 L1 Small Phillips and flat blade screwdrivers LI Pliers with wire cutter HCARO630 Sealing Iron TOPR2100 L1 Heat gun TOPR2000 T Pins HCAR5150 L1 Straightedge with scale 0475 I Cutting mat 0456 L1 Builder s triangle HCARO0480 L1 1 4 20 Tap and Drill set GPMR8105 drill bit included LI Tap handle GPMR8120 1 Masking Tape TOPR8018 1 Monofilament string for aligning the wing and stabilizer LJ Panel line pen 2510 L Groove Tube GPMR8140 L1 Dead Center Hole Locator GPMR8130 L1 Precision Hinge Marking Tool GPMR4005 Microballoons TOPR1090 Optional Supplies and Tools 1 CG Machine GPMR2400 1 Accu Throw Deflection Meter GPMR2405 L1 CA Applicator tip
3. 83M Nuv3HS VS 91 1 M3ovds YWdS 491 1 1002 30 AVML NOMTIIV Ald 8 1 102 310 532319 dil 9NIM vsiva 8 1 102 310 YvdS 9NIM QuVMHO4 GOOMSSVE 91 X 91 3903 9NIQV31 9NIL33HS 3903 9NIQV31 3903 9NIQv31 8015 VSV8 OE X 9 6 X 9 1 VSWB X X 9 1 30018 YINI ONIM MOG SNM VSIVE O X 8 9 X QOOMQMVH v 1 2Z X 1 vSiva 8 6 X 8 1 8 X 1 4 X 15 BASSWOOD WING SPAR DOUBLER 1 8 X 1 4 X 30 BASSWOOD WING SPAR 1 4 X 2 1 4 HARDWOOD WING DOWEL 3 32 X 5 8 X 30 BALSA y Ero 3 16 X 3 16 BASSWOOD SUB LEADING EDGE 1 4 X 3 4 X 30 BALSA 1 16 X 3 X 30 BALSA FORWARD WING SPAR DIE CUT 1 8 PLY WING LEADING EDGE dos EDGE SHEETING FORWARD WING JOINER 3 16 X 3 16 BASSWOOD CROSS SECTION 5 FORWARD WING SPAR TA _ DTT Us p DIE CUT 1 8 PLY i CENTER WNG JOINER M ER EIE gt ra IE A DIE CUT 1 8 PLY i T DIE CUT 1 16 PLY 1 16 BALSA AILERON TRAY j DIE CUT 1 16 PLY 0 SPAR SPACER SHEAR WEB i CENTER WING JOINER 1 8 X 1 4 X 30 BASSWOOD 1 16 X 1 2 X 24 BALSA ANS SPAR DIE CUT 1 8 PLY WING TE SHEETING STRUT PLATE CENTER SHEETING RIGHT WING PANEL E CENTER SHEETING DIE CUT 1 8 BALSA 29 3 8 X 3 8 BALSA TOP VIEW WING GUSSET WING TIP FILLER BLOCK LEADING EDGE AND CENT
4. 2 xd 5 9 CUT SLOT WITH HOBBY KNIFE AND 11 BLADE Cut the hinge slots in the elevators stabilizer fin and rudder using a Hobby Knife with a 11 blade Begin by carefully cutting a very shallow slit at the hinge location to accurately establish the hinge slot Make three or four more cuts going a little deeper each time As you cut slide the knife from side to side until the slot has reached the proper depth and width for the hinge L1 18 Cut the 3 4 x 1 hinges for the elevator and rudder from the supplied 2 x 9 hinge material then snip off the corners Temporarily join the elevators to the stab and the rudder to the fin with the hinges adjusting any hinge slots if necessary so they all align Do not glue in the hinges until you are instructed to do so Finish the Tail Surfaces 1 Use a Precision Hinge Marking Tool to mark the centerline on the LE of the elevator Mark a bevel to line on both sides of the elevator LE about 3 32 from the LE L1 2 Using the bevel to lines and the centerline as a guide make the V on the leading edge of the elevators with a razor plane or your bar sander with 150 grit sandpaper L1 3 Use the same procedure to bevel the leading edge of the rudder 1 4 Temporarily attach the elevators to the stab and the rudder to the fin Use your bar sander to round the perimeter of the elevator stab rudder and fin do not round the bottom edge of the fin where
5. L1 22 Cut the 36 gray outer pushrod tube in half Carefully sand the outside of the tubes with coarse sandpaper so the glue will stick better L1 23 Insert the outer pushrod tubes through the 3 16 holes in formers F 4 F 5 and out the exits next to F 6 Leave about 1 2 of the pushrod tubes in front of former F 4 Glue the tubes to the formers and fuse sides The slots in the side of the fuse for the pushrod tube exit can be filled with Hobbico balsa filler or a 50 50 mixture of microballoons and epoxy L1 24 After the filler has cured use a sanding bar to sand the pushrod tubes and filler flush with the side of the fuselage L1 25 Position the fuse upside down on your building board Check that the aft end of the fuse is perpendicular to the building board when viewed from the rear Sand the bottom of the fuse sides and formers flush Sheet the bottom of the fuse with 1 16 x 3 x 30 balsa sheet applied cross grain starting at the rear edge of the landing gear rail and proceeding to the aft end of the fuse and from the front of the landing gear rail to the firewall Note A good way to do this is to lay the sheet across the fuselage and mark the edge of the longerons on the bottom of the sheet Then remove the sheet and cut along the mark with a hobby knife allowing a little extra that will be sanded off later 126 Use a sanding block to sand the bottom sheeting flush with the side of the fuse Install the Engine
6. Reinstall the CA hinges in the elevator without glue INSTALLING CA HINGES The hinge material supplied in this kit consists of a 3 layer lamination of mylar and polyester It is specially made for the purpose of hinging model airplane control surfaces Properly installed this type of hinge provides the best combination of strength durability and ease of installation We trust even our best show models to these hinges but it is essential to install them correctly Please read the following instructions and follow them carefully to obtain the best results These instructions may be used to effectively install any of the various brands of CA hinges The most common mistake made by modelers when instaling this type of hinge is not applying a sufficient amount of glue to fully secure the hinge over its entire surface area or the hinge slots are very tight restricting the flow of CA to the back of the hinges This results in hinges that are only tack glued approximately 1 8 to 1 4 into the hinge slots The following technique has been developed to help ensure thorough and secure gluing TEMPORARY PIN TO KEEP HINGE CENTERED It 15 best to leave a very slight hinge gap rather than closing it up tight to help prevent the CA from wicking along the hinge line Make sure the control surfaces will deflect to the recommended throws without binding If you have cut your hinge slots too deep the hinges may slid
7. sparks or flames as fuel is very flammable Do not smoke near the engine or fuel and remember that the engine exhaust gives off a great deal of deadly carbon monoxide Therefore do not run the engine in a closed room or garage Get help from an experienced pilot when learning to operate engines 46 Use safety glasses when starting or running engines Do not run the engine in an area of loose gravel or sand the propeller may throw such material in your face or eyes Keep your face and body as well as all spectators away from the plane of rotation of the propeller as you start and run the engine Keep items such as these away from the prop loose clothing shirt sleeves ties scarfs long hair or loose objects pencils screw drivers that may fall out of shirt or jacket pockets into the prop Use a chicken stick device or electric starter follow instructions supplied with the starter or stick Make certain the glow plug clip or connector is secure so that it will not pop off or otherwise get into the running propeller Make all engine adjustments from behind the rotating propeller The engine gets hot Do not touch it during or after operation Make sure fuel lines are in good condition so fuel will not leak onto a hot engine causing a fire To stop the engine cut off the fuel supply by closing off the fuel line or follow the engine manufacturer s recommendations Do not use hands fingers or any body part to try to s
8. FCF DIE CUT 1 8 BALSA FORWARD CENTER FUSE FCF im DIE CUT 1 8 BALSA FORWARD CENTER 6 52 X 1 MACHINE SCREW FUSE FCF 1 8 X 3 8 1 16 X 3 BALSA DIE CUT 3 32 BALSA BALSA LONGERON m d ae a BOTTOM SHEETING 6 WASHER LOWER FUSELAGE DOUBLER 1 8 X 3 8 BALSA s BOTTOM SHEETING mov DE CUT 3 32 BALSA SUPPORT LONGERONS FOR A 2 STROKE LOWER FUSELAGE DOUBLER Et reer er uu 2 5 FORWARD LOWER FUSE FLF 1 16 X 3 BALSA LH 2 X 3 8 SHEET 5 E BOTTOM SHEETING A METAL SCREW DIE CUT 3 16 BALSA DIE CUT 3 16 BALSA RUDDER FRAME S FIN FRAME DIE CUT 1 8 BALSA DIE CUT 3 32 BALSA prese DIE CUT 1 8 BALSA ER FORWARD LOWER FUSE FLF LOWER FUSELAGE DOUBLER FORWARD LOWER FUSE FLF ERU NE 1 8 X 3 16 BALSA CROSS BRACES ALL CROSS SECTIONS CUT FROM 1 8 X 3 16 X 30 BALSA STICK ARE VIEWED FROM BALANCE RANGE DIE CUT 1 8 BALSA 3 8 X 3 4 X 1 3 8 THE FRONT FORWARD TOP FUSE FTF Cae 2444 WINDSHIELD d SMS IN 1 490 x 2 ae WING BOLT CUT FROM 1 8 X 3 16 X 30 BALSA STICK 2 6 32 X 1 MACHINE SCREW DIE CUT 3 32 BALSA DIE CUT 1 8 PLYWOOD UPPER FUSELAGE DOUBLER AFT DECK BASE 3 16 X 3 8 BALSA 3 16 X 3 8 BALSA 6 WASHER 1 85 X 1 4 BALSA FIN FRAME RUDDER FRAME COWL TOP WINDOW FRAME s 1 8 DOWEL S
9. T NL OUT 5 10 BALSA WE CUT 1 87 BALSA LOWER FUSELAGE SEMENG EDGE 1 8 X 3 16 BALSA CROSS BRACES eet m amp DE CUT 3 18 BALSA W qr STABILIZER CENTER 1 8 X 3 16 BALSA CROSS BRACES L1 4 Finish constructing the stab frame from a 3 16 x 3 8 x 30 balsa stick 3 t i 3 87 BALSA LONGERON SEE Co U 3 32 BALSA fni DOUBLES DIE CUT 3 16 BALSA LEAGING EDGE DOUBLER DE CU 3 LOWER FUSELACE DIE CUT 1 87 BALSA z LOWEN FUSELAGE t a x 3 16 GALIA 7152 055 BRACES DIE CUT 3 36 BALSA MCA UP 16 BAU SIABILIZER CENTER _ 0 7 FRAME dee fon 1 w CO A 1 8 X 3 16 BALSA CROSS B moe 0 de EX 2 LARGE NYLON CONTROL HORN 5 From the 1 8 x 3 16 x 30 balsa stick cut and glue the stab braces to the stab frame _1 6 Remove the stab from your building board Inspect glue and sand as you did with the fin 1 8 X 3 16 BALSA CROSS BRACES CUT FROM 1 8 x 3 16 x 20 BALSA SPECK TH tte LARGE NYLON CONTROL HORN NYLONOZ LJ 7 From a 3 16 x 3 8 x 30 balsa stick cut the elevator leading edge to length and pin it over the elevator plan Pin and glue the die cut 3 16 balsa elevator counter balance 8 to the LE Construct the remaining elevator frame from a 3 16 x 3 8 x 30 balsa stick 11418 From the
10. With F 2A inserted into the notches perpendicular to the fuse side use thin CA to glue the former in place 23 L1 2 Use the die cut 1 8 plywood former gauge 4 to hold the die cut 1 8 plywood former F 4 at the proper angle to the fuse side while gluing the former in place L1 3 Lay the fuse on its left side and insert former F 2A into the notches on the left side With F 2A perpendicular to the to the left fuse side glue the former to the fuse side 4 Install the die cut 1 8 plywood former F 3 into the notches in the left and right fuse sides Do not glue the former to the fuse sides _1 5 Lay the fuse on its left side Use former gauge 4 to hold F 4 in position while gluing it to the fuse side L1 6 Use a sanding bar to taper the inside of the aft end of the fuse sides so that when the aft fuse sides are brought together the two ends are approximately 3 16 wide 17 Test fit the die cut 1 8 plywood former F 6 at the aft end of the fuselage Position the fuselage right side up over the plan top view with formers F 3 and F 4 aligned with the plan Pull the aft end of the fuselage together checking the fit between the sides and sanding if necessary L1 8 Pin the fuse over the fuselage top view Carefully line up the aft end Use a building square to make sure the fuse sides are perpendicular to the building board Then glue the aft end of the fuse together and former F 6 to the fuse sides Note
11. any case please start at the location we recommend Do not at any time balance your model outside the recommended range L1 2 With all parts of the model installed ready to fly and the fuel tank empty lift the model at the balance point If the tail drops the model is tail heavy and you may want to move the receiver battery forward to balance the model If the nose drops it is nose heavy and you may want to move the receiver battery toward the tail to balance the model It is best to try balancing the plane by moving the receiver and receiver battery f you are unable to obtain good balance by moving the receiver and receiver battery then it will be necessary to add weight to the nose or tail to achieve the proper balance point SET THE CONTROL THROWS 4 CHANNEL RADIO SETUP STANDARD MODE 2 ELEVATOR MOVES UP RIGHT AILERON MOVES UP LEFT AILERON MOVES DOWN RUDDER MOVES RIGHT CARBURETOR WIDE OPEN The throws are measured at the widest part of the elevators rudder and ailerons Adjust the position of the pushrods at the servo horns and the nylon control horns to change the amount of throw You may also use the ATV s if your transmitter has them We recommend the following control surface throws Low rate 5 16 up 5 16 down 1 2 right 1 2 left 7 16 up 7 16 down High rate 1 2 up 1 2 down 1 right 1 left 5 8 up 5 8 d
12. plywood dihedral gauge against the root end of the bottom main spar With the root end of the top main spar against the dihedral gauge insert and glue the spar into the notches in the top of the ribs LI L1 14 Center the 3 32 x 5 8 x 30 balsa sub LE on the front of the ribs Check that the jig tabs at the aft end of the ribs are against the building board Then glue the sub LE in position 1 8 X 1 8 BASSWOOD FORWARD WING SPAR Cut wow s w x 267 Be iie L1 L1 15 From the 3 16 x 3 16 x 24 basswood stick cut two forward spars 6 long Align the dihedral gauge with the centerline of the wing Glue the forward spars in the top and 13 bottom of ribs W 2 and W 3 with the root ends against the dihedral gauge Make sure that these forward spars are against the back edge of the slot in W 2 11416 Cut the 3 32 x 7 8 x 24 balsa stick in half to make the aileron bay TE Glue one of the TE pieces centered on the aft end of the W 4 through W 6 ribs and the sub TE L1 L1 17 Cut one of the 1 16 x 1 2 x 24 balsa TE sheets in half Test fit the TE sheet in the recess at the aft end of the W 4 through W 6 ribs and trim as necessary D 18 From the 1 16 x x 30 balsa sheet cut and glue vertical grain shear webs to the spars in the locations shown on the plan It is not necessary for the shear webs to be glued to the ribs Make sure they are glued securely to the wing spars
13. side with the embossed lettering on it is the front of the formers 22 114 Use 6 minute epoxy to glue the two die cut 1 8 plywood firewall spacers to the back of F 1B on the left side The spacers will set the right thrust in the firewall when the firewall is installed in the fuselage IF USING GREAT PLANES ENGINE MOUNT DRILL 5 32 HOLES FOR BLIND NUTS IF NOT INSTALLING THE GREAT PLANES ENGINE MOUNT CONNECT THE OUTER PUNCH MARKS TO CENTER THE ENGINE MOUNT 115 After the epoxy has cured drill 5 32 holes at the four engine mount punch marks NOTE If you will be using an engine mount other than the Great Planes engine mount draw centerlines connecting the outer punch marks Use the centerlines to align your engine mount on the firewall Drill 5 32 holes at the appropriate locations L1 16 Press four 6 32 blind nuts into the holes from the back of the firewall Tap the blind nuts with a hammer to fully seat them Apply a few drops of thin CA around each blind nut to secure them in position Avoid getting CA on the threads of the blind nuts L1 17 Glue the die cut 1 8 plywood former F 2B to the back of former F 2A 18 Drill 3 16 holes through the punch marks at the locations shown on the die cut 1 8 plywood formers F 4 and F 5 These holes are for mounting the outer pushrod tubes Join the Fuselage Sides 1 Install former F 2A on the right fuse side so that the embossed F 2A faces forward
14. stab so that the TE corners are equal distance from the center of the fuselage The LE of the stab should be flush with the forward edge of former F 6 and the TE approximately 3 8 from the aft end of the fuse From a few feet behind the fuselage view the stabilizer checking that the stabilizer is parallel with the wing If not remove the stabilizer and sand the saddle slightly When satisfied with the fit use 30 minute epoxy to glue the stab to the fuse Double check the stab alignment while the epoxy is curing 30 2 SLOT FOR ELEVATOR JOINER WIRE L1 3 Set the fin in position on the stab The fin TE must line up with the aft edge of the fuse The bottom of the fin TE may need to be sanded slightly to allow the fin to seat on the stab Cut a slot in the forward edge of the TE so that the joiner wire will fit between the fin and the stab TE L 4 Sight down the fin checking that it is in line with the centerline of the fuselage It is very important that the fin be aligned with the centerline of the fuse and perpendicular to the stab If it is not the plane will be difficult to trim Use 30 minute epoxy to glue the fin to the stab aft deck base and former F 6 L1 5 Mark the location of the tailgear wire on the rudder and the nylon tailgear bearing on the fuselage 16 Drill a 3 32 hole in the leading edge of the rudder at the mark you made for the tailgear wire Then cut a groove for the nylon tailgear bearing Tes
15. Do not install shear webs in the rib bays between ribs W 1 and W 3 DIE CUT 1 16 PLY WING JOINER ru oz CENTER i L1 L1 19 Use the dihedral gauge to mark the TE at the wing center Trim the TE along the line 11120 Remove the wing from your building board and install the second piece of 1 16 x 1 2 TE sheet on the bottom of the wing Note The TE sheet will need to be bent to meet rib W 6 L1 21 Return to step 4 and build the left wing panel 1 Draw a centerline on the two die cut 1 8 plywood center wing joiners and the two die cut 1 16 plywood outer wing joiners L1 2 Use epoxy to glue the two center wing joiners together aligning the centerlines and the edges 14 L1 3 Assemble the die cut 1 8 plywood wing tip crutch and crutch feet Do not glue the feet to the tip crutch L1 4 Trim the jig tabs off the bottom of the double W 4 ribs on the left wing panel Sand the bottom of the ribs TE sheet and aileron bay TE flush on the left wing panel L1 5 Position the left wing panel on your flat building board Place the wing tip crutch under the double W 4 ribs The TE on the tip crutch should be toward the TE and the crutch should be flush with the TE L1 6 Insert the center wing joiners between the main spars the outer wing joiners on the front and back of the main wing spars and the die cut 1 8 plywood forward joiner in the right wing Slide the right wing half with the jo
16. alternating every other rib bay Pin the main spar cut in step 6 over the shims aligned with the wing plan at the wing root Glue two of the die cut 3 32 balsa W 4 ribs together to make the W 4 outer rib L1 9 Glue the die cut 1 16 ply W 2 spar spacer to the tip side of rib W 2 centered between the main spar notches and the lightening holes Trim the main spar notches for the 1 16 plywood wing joiner 12 wm Pop nae Ws hanin ee 1142 10 Pin and glue the die cut 3 32 balsa W 2 W 3 W 4 and W 6 ribs and the die cut 1 8 balsa W 5 rib onto the main spar perpendicular to the building board Note There is a W 3 and W 4 rib glued together at the root of the aileron bay The main spar will need to be bent upward to contact the W 6 rib L1 L1 11 Position the 1 8 to 11 32 x 3 4 x 18 shaped balsa trailing edge on the jig tabs of the W 2 and W 3 ribs flush with the outside of rib W 3 Use a straight edge to align the top of the TE with the top of the ribs When satisfied with the fit glue the TE to the ribs Note The TE extends 1 16 above rib W 2 to allow for the 1 16 center sheeting a x 24 5k EE TIN cr e x i Hu WNG SON E L1 12 Fit and glue the 1 4 x 1 4 x 30 balsa sub TE the notches at the rear of the W 4 and W 5 ribs Butt glue the sub TE to rib W 6 SA 7 AINST DIHEDRALGAUGE 40 we A 11113 Hold the die cut 1 8
17. engine on the engine mount Cut out the holes marked in the last step slightly smaller than drawn Test fit the cowl over the engine adjusting the size and position of the holes as needed 1 9 Using the template method locate the four cowl mounting screw holes The mounting screws must screw into the sides of the firewall With the cowl in position mark and drill a 1 16 pilot hole at each mark Enlarge the holes in the cowl to 3 32 Use 2 washers and 2 x 3 8 sheet metal screws to attach the cowl to the fuse Construct the Wing Struts Note The wing struts are for scale like appearance only Built according to the plan and instructions the airframe has sufficient strength for normal aerobatic flying without the struts We suggest that the wing struts be removed if the plane will be flown fast If not the struts may flutter at high speeds Before proceeding make sure that you have the wing seated and installed on the fuselage in its final position 12 1 Cut a 3 16 x 1 2 x 30 balsa stick in half to make two wing struts 1 L 2 Taper and round the LE and TE of the wing struts to an airfoil shape as shown on the wing plan Cut three CA hinge pieces 1 4 x 1 L1 4 Cut a slot 1 2 deep one end of each wing strut Insert a CA hinge into each slot and glue them in place with thin CA Drill a 1 16 hole through the center of the protruding CA hinges 37 5 Glue a
18. former F 5 on the longerons 1 5 Remove the fuselage side from the plans Return to step 1 and build the second fuselage side L1 6 Place the two fuse sides together and check that they match up all the way around If they are not identical pin them together and use a sanding bar to make them match _1 7 Lightly sand both sides of each fuselage side to remove any excess glue 21 L1 8 Lay the fuse sides next to each other so they mirror each other Mark one fuse side left side and one right side 119 Glue the die cut 3 32 balsa wing saddle doublers to the inside of both fuse sides Align the top and front of the doubler with the top and front of the fuse side L 10 Glue the die cut 3 32 balsa lower fuse doublers to the inside of both fuse sides Align the bottom and front of the doubler with the bottom and front of the fuse sides 1111 Glue the die cut 3 32 balsa aft stabilizer doublers to the inside of both fuse sides Align the top of the doubler with the top of the fuse side and the front edge of the notch in the doubler with the aft edge of the top longeron The aft edge of the doubler will be approximately 3 8 forward of the aft edge of the fuse side to the lower fuse doublers Align the landing gear support with the top and front of the notch for the landing gear rail L1 13 Use 6 minute epoxy to glue the front of die cut plywood firewall former F 1B to the back of former F 1A Note The
19. pilot holes at the marks Temporarily mount the control horn to the aileron with 2 x 3 8 sheet metal screws _1 L1 4 With the aileron servo centered and the aileron in the neutral position use a felt tip pen to mark where the aileron pushrod crosses the mounting holes in the servo arm L1 L1 5 Make a 90 degree bend at the mark you made Temporarily install a nylon FasLink on the pushrod and cut the wire so it slightly protrudes out of the FasLink 6 Remove the two 2 x 3 8 sheet metal screws from the control horn Put a couple of drops of thin CA into both screw holes in the aileron to strengthen the wood After the CA cures reattach the control horn L1 7 Return to step 1 of Install the Aileron Pushrods and install the other aileron servo and pushrod BALANCE THE AIRPLANE LATERALLY SPECIAL NOTE Do not confuse this procedure with checking the or balancing the airplane fore and aft That very important step will be covered later in the manual Now that you have the basic airframe nearly completed this is a good time to balance the airplane laterally side to side Here is how to do it L1 1 Temporarily attach the wing and engine to the fuselage L1 2 With the wing level lift the model by the propeller shaft and the bottom of the rudder this may require two people Do this several times If one wing tip consistently drops when you lift the plane it means that side is heavy Balance t
20. score along the cut lines and flex the plastic until the excess breaks free or use Hobbico Curved tip Canopy Scissors to cut along the lines Save the leftover ABS cut from the pant halves For now don t worry about accurately cutting out the opening in each wheel pant half just cut an approximate opening for the wheels L1 J 2 Use your bar sanders to carefully true the edges of the wheel pant halves so that when you glue them together the seam will be as small and straight as possible Use 150 or 220 grit sandpaper to remove the flashing and thoroughly roughen the inside of the wheel pant halves 3 Test fit the wheel pant halves and make adjustments where necessary for the best possible fit LJ L1 4 Glue the die cut 1 8 plywood wheel pant mount around the indentation on the inside of the wheel pant 5 Use masking tape to join the two wheel pant halves Carefully spot glue them together in just a few places with thin CA Start by spot gluing the top then the front and rear After the halves are joined securely glue them along all seams with thin CA Note Do not use CA accelerator on the ABS plastic as it may develop cracks and or keep the paint from adhering 5 From the leftover ABS trim and glue strips to the inside of the wheel pant along the seams 1146 To reinforce the wheel pant use epoxy to glue the fiberglass tape over the seam on the inside of the wheel pant 34 L1 7 Use your hobb
21. sheeting until the epoxy cures 17 L1 28 Complete the partial die cutting of the aileron servo bay in rib W 5 ES 111129 Test fit the die cut 1 8 plywood aileron servo tray sides and top in the aileron servo bay Lay a straightedge across the top of the servo tray from the forward wing sheeting to the TE sheeting Position the aileron servo tray so that it is flush with the forward and TE sheeting When positioned correctly glue the servo tray sides to W 5 and shear webs and the top of the tray to the sides of the tray 1114130 Glue the die cut 1 8 balsa gusset in the corner the outside rib W 3 and the shaped TE 11431 Glue the two die cut 1 8 ply wing strut plates to the W 4 ribs main spar and aileron TE sheet in position The wing strut plates must be flush with the bottom of the wing L1 32 Go back and repeat steps 28 through 30 on the other wing half Assemble the Ailerons ae qR s E eM S 77 Li Dm d _J LJ 1 Position the die cut 1 8 balsa aileron base over the plan Mark the aileron rib locations on both sides of the aileron base LJ 2 Cut the 3 8 x 1 x 24 balsa aileron LE in half Draw a centerline lengthwise on the 1 x 12 side 11143 Glue the aileron base on the aileron LE along the centerline and perpendicular to the face of the LE 18 LJ L1 4 From the 3 32 x 3 8 x 30 balsa sticks cut and glue aileron ribs
22. the leftover white nylon inner pushrod Thread a nylon clevis 14 turns onto the 1 stud L1 Insert the throttle pushrod in the throttle outer pushrod tube from the inside of the fuse L1 4 Position the throttle servo arm so that it is adjusted to the aft position Measure and cut the white inner pushrod 1 2 forward of the firewall 40 15 Cut off 1 2 of the thread from the 2 56 x 6 pushrod Thread the pushrod into the white inner pushrod forward of the firewall Hint Make a small 90 degree bend at the non threaded end of the pushrod to hold on to Carefully hold the white inner pushrod with a pliers while threading the pushrod into the inner pushrod 16 Attach the screw lock pushrod connector to the throttle arm of the engine Insert the pushrod through the pushrod connector and adjust the throttle Install the Aileron Pushrods 1 Install the grommets and brass eyelets one of the aileron micro servos and install the servo in the wing using the hardware from your radio system 1142 Thread a nylon clevis approximately 14 turns onto the end of a 2 56 x 12 metal pushrod Remove the backing plate from a small nylon control horn and connect the clevis to the horn in the outer hole 3 Position the control horn refering to the sketch in step 7 on page 39 on the aileron as shown on the plans Mark the location of the control horn mounting holes and drill 1 16
23. the wing tip and sand the top and bottom edges of the tip support to blend into the wing tip 1145 From the 3 8 x 3 8 x 8 balsa stick cut and glue tip blocks to the top of the wing tip TE and the top and bottom of the wing tip LE 20 1116 Shape the tip blocks to blend in to the edge of the wing tip LE and TE Sand a radius on the edge of the wing tip 1 7 Return to step 1 of Assemble and Install the Wing Tips and build the second wing tip BUILD THE FUSELAGE Assemble the Fuselage Sides a Wa F Jd a ENE N we c lt lt E T ad 6 OLL Y i A SUPPORT DIE CUT 1 8 BALSA LANDING GEAR COVER L1 L 1 With waxed paper Plan Protector positioned over the fuse plan pin the die cut 1 8 balsa forward lower fuselage FLF forward center fuselage FCF and forward top fuselage FTF in position over the plan and glue together Important Save the leftover balsa from the 1 8 die sheets for use later when making wing shims L1 LJ 2 Pin the 1 8 die cut balsa fuse side AFS in position over the plan From the 1 8 x 3 8 x 30 balsa sticks fit and glue three longerons to fit between the forward fuse and the aft fuse side D 1143 From the 1 8 x 1 4 x 12 balsa stick cut and glue the side window frame to the forward center and forward top fuselage sides L1 4 Use a pen to mark the location of
24. to room temperature This allows the propellant and some of the thinner to evaporate out of the paint Depending on the amount of paint in the jar this process may take about 1 hour 42 After allowing the propellant to boil off use an airbrush to spray paint the windshield If the paint is too thick to spray properly it can be thinned with a small amount of lacquer thinner Do not thin with more than 40 thinner In general about 10 thinner will adequately thin the paint for airbrushing The paint can also be brushed on but brushing will not produce the high quality finish of spraying Allow the paint to dry overnight before gluing it on the plane We recommend that the windshield be glued on within 48 hours of being painted If you have any doubt about the material you are painting we suggest that you try painting on a small piece of leftover material and watch it for a few days to be sure that you are satisfied with the end results We used LustreKote White TOPR7204 and True Red TOPQ7227 to paint the cowl wheel pants and windshield The inside of the fuselage was brushed with flat black in the cabin area FINAL HOOKUPS CHECKS Install the Hinges L1 1 Cut the covering from the hinge slots in the elevator and stab Also cut the covering from the groove for the elevator joiner wire and the tailgear wire L1 2 Clean the elevator joiner wire with alcohol and a paper towel to remove any oil residue L1
25. 1 8 x 3 16 x 30 balsa stick cut and glue the elevator cross braces to the frame 19 Repeat steps 7 and 8 to build the second elevator half _1 10 Remove the elevators from your building board Inspect glue and sand as you did with the fin LARGE NYLON ELEVATOR JOINER WIRE CONTROL HORN WBNTO70 1111 Pin both elevators in position over the plan Lay the 3 32 elevator joiner wire on top of the elevators in the position shown on the plan Use a pencil to lightly mark the outline of the joiner wire on the elevators 1 12 Using a straightedge extend the sidelines of the elevator joiner outline forward to the leading edge Also use a Precision Hinge Marking Tool to draw a centerline on the leading edge Using these lines you can determine exactly where to drill the holes for the elevator joiner wire 13 Drill a 3 32 hole into the leading edge of both elevators As you drill each hole keep the drill aligned with the top and bottom surface of the elevator and reference lines you made in the previous steps L 14 Use the Great Planes Groove Tube to cut a 3 32 groove in the leading edge of both elevators to recess the joiner wire Note If you do not have a Groove Tube refer to the Following Expert Tip Ue Soe WS HOW TO CUT A GROOVE FOR A JOINER WIRE A Use a 11 knife blade to sharpen the inside of a piece of 3 32 brass tube Roll the tube as you carve the end B Use the sharpen
26. 6 and the center crutch at the center of the wing The F on the center crutch goes to the front 16 L1 19 Locate the 1 4 x 2 1 4 hardwood wing dowel Round both ends of the dowel for ease of insertion Test fit the 1 4 dowel in the forward wing joiner and rib W 1A Use a 1 4 drill bit to clean out the hole if needed Use epoxy to glue the dowel in the forward wing joiner and W 1A as shown on the plans SEPARATE SHEETING 20 Sheet the bottom of the wing following the same procedure used to sheet the top of the wing Note A separate piece of 1 16 balsa sheeting is used to sheet between the double W 4 ribs and rib W 6 121 Trim and sand the 1 16 bottom wing sheeting flush with rib W 6 the forward wing joiner and the sub TE LI 22 Glue the 1 4 x 3 4 30 balsa leading edge to the sub LE and wing sheeting L1 23 Use a razor plane and sanding bar to shape the LE to the shape shown on the wing plan L1 24 Remove the jig tabs from the top of the ribs Use a sanding bar to sand the entire wing smooth L1 25 Draw a centerline on the die cut 1 16 plywood wing bolt plate 126 Use a sanding bar to bevel the front and sides of the wing bolt plate to a sharp edge 127 Use 6 minute epoxy to glue the wing bolt plate on the top of the wing aligning the centerline on the plate with the centerline of the wing and flush with the TE Use masking tape or clamps to hold it tight against the wing
27. A small misalignment here will throw the aft end out of line so double check before gluing 24 1 9 Test fit the die cut 1 8 plywood aft deck base between the top longerons F 4 and F 6 Check that the fuse sides are perpendicular to the building board Then glue the aft deck base to the top longerons F 4 and F 6 1110 Position the die cut 1 8 plywood former F 5 between the longerons Insert the tab on the top of F 5 into the slot in the aft deck base Align the former with the lines you put on the longerons Glue the former to the longerons and the aft deck base P 3 1111 Now glue former F 3 to the fuse sides A 12 Temporarily install the die cut 1 8 plywood front deck The shorter side of the deck is positioned on the right side L1 13 Test fit the firewall on the front of the fuse The spacers on the back of the firewall are positioned on the left side The firewall fits against the front deck and the lower fuse doubler 14 When satisfied with the fit of the firewall use CA to glue the front deck to the fuse sides and former F 2 Do not glue the front deck to the firewall yet L1 15 Use 30 minute epoxy to glue the firewall to the fuse sides and front deck Before the epoxy cures wipe off any excess epoxy using a paper towel dampened with rubbing alcohol Use clamps to hold the fuse sides tight against the firewall until the epoxy cures L1 16 From the 1 4 x 1 4 x 24 basswood stick cut a
28. EET METAL SCREW NYLON LANDING GEAR STRAP Nes 2 1 2 WHEEL CUT THE CA HINGE STRIP INTO 3 4 X 1 PIECES 5 32 MAIN LANDING GEAR DIE CUT 3 16 BALSA ELEVATOR COUNTERBALANCE FUSE PLAN PLAN NO TYL2PO2 2 X 3 8 SHEET METAL SCREW DIE CUT 1 8 PLY WHEEL PANT RETAINER NYLON LANDING GEAR STRAP 5 32 WHEEL COLLAR DIE CUT 1 8 PLY WHEEL PANT MOUNT QUESTIONS e mail us at productsupport greatplanes com 2 1 2 WHEEL WHEEL PANT CROSS SECTION DESIGNED DRAWN AND INSTRUCTIONS BY MARK HAMPE CA HINGE or call 217 398 8970 1 8 X 3 16 BALSA 3 16 X 3 8 BALSA Visit our Web Site at CROSS BRACES 1e X 3 FRAME www greatplanes com LARGE NYLON ELEVATOR JOINER WIRE CONTROL HORN ALL COMMERCIAL RIGHTS RESERVED P 0 Box 788 Urbano Illinois 61801 217 398 8970 3SV8 NHOH NON3IIV 31V d 1108 ONIM 3903 ONMIVYL ONIM 3sv8 Ald 8 1 1002 30 91 1 102 30 YSI 81 X v X 27 0 OL 8 1 Q3dvHs VS V8 8 1 1no 3ld ec See ald NON3IIV AllHV1O Q3AOW3H ONIL33HS H31N3O 3903 vSW8 8 X 2 lt 3903 9NIOV31 NO33IIV _ VSI YZ X al X 8 M3I dOL r XINI 9NIM 9NIA 1331 SSS Sr X cay vS1V8 8 1 1n2 3ld qim de ALVId Lus Ald 8 1 1n9 3ld MvdS QOOMSSV8 OE X v X 8 1
29. ER SHEETING ARE REMOVED FOR CLARITY LE 3 8 X 1 X 24 BALSA f AILERON LEADING EDGE DIE CUT 1 8 BALSA WING TIP PIECES NYLON FASLINK 074 X 12 WRE PUSHROD SILICONE CLEVIS RETAINER SMALL NYLON CONTROL HORN 3 32 X 3 8 BALSA T T AILERON RIB 2 x 3 8 ROUND CORNERS SHEET METAL SCREW DIE CUT 3 32 5 TYPICAL WING STRUT BALSA RIB W 4 SHAPED 1 8 TO 11 32 X 3 4 X 18 BALSA DIE T 1 87 BAKSA CROSS SECTION WING TRAILING EDGE DIE CUT 1 8 PLY AILERON HORN BASE WING PLAN PLAN NO TYL2PO SHAPED BALSA DIE CUT 1 8 PLY WING STRUT FUSELAGE STRUT mw MOUNTING PLATE rl TYL2WO A CA HINGE 3 16 X 1 2 BALSA CA HINGE 7 FUSELAGE DI CUT 1 8 WNG STRUTS QUESTIONS DESIGNED DRAWN AND INSTRUCTIONS BY MARK HAMPE PLYWOOD AFT STRUT MOUNTING 2 X 3 8 PLATE e mail us at productsupport greatplanes com CA HINGE MATERIAL Grma METAL mao or call 217 398 8970 NYLONB7 SCREW Visit our Web Site at e 2 X 3 8 SCRWO24 www greatplanes com SHEET METAL CO SCREW VIEW OF STRUT MOUNTING E CD Ry A ScRWO24 ALL COMMERCIAL RIGHTS RESERVED 2000 Box 788 Urbana Illinois 61801 217 398 8970
30. Marais bates 3 DECISIONS YOU MUST MAKE 3 Engine Selection 3 5 3 Required Accessories 3 Bulldirig Supplies uu ura a notes See sss 4 I T 4 Optional Supplies And 4 Common Abbreviations 4 Types Of Wood 5 Metric 5 Important Building 5 5 Die Patterns aad aaan a odode dde dos 6 BUILD THE TAIL SURFACES 7 Build The Fin And Rudder 7 Build The Stabilizer And Elevators 7 Finish The Tail 10 BUILD THE WING 11 Build The Wing 11 Join The Wing Panels 14 Assemble The Ailerons 18 Assemble And Install The Wing Tips 20 BUILD THE FUSELAGE 20 Assemble The Fuselage Sides 20 Join The Fuselage Sides 23 Install The Engine 27 Sheet The Front 27 Sand The Tuselage tat tadaa de SAC Rcs 28 Mount The Wing To The Fuselage 29 Mount The Stabilizer And Fin 29 Install The Dowel Stringers 31 Moun
31. NT MOUNT IT j TYL2F04 1 8 X 5 3 4 X 15 3 4 PLYWOOD LANDING GEAR RAIL SUPPORT ELEVATOR COUNTER BALANCE TYL2SO1 1 PER KIT lt ZA 2 2 A 1 3 16 X 3 X 12 BALSA d ELEVATOR COUNTER BALANCE 1 8 X 5 3 4 X 23 3 4 PLYWOOD 7 1 8 X 3 1 2 X 19 PLYWOOD FUSE STRUT AILERON TRAY MOUNTING PLATE AILERON BASE TYL2WO5 2 PER KIT WII nr fy ones S lt 122222 1 8 X 3 X 18 BALSA AILERON HORN BASE STRUT PLATE WING GUSSET 6 BUILD THE TAIL SURFACES Build the Fin amp Rudder L1 1 Cover the fin rudder portion of the plan with wax paper or Great Planes Plan Protector L1 2 Pin the die cut 3 16 balsa fin frame V 1 in position on the fuse plan 1 8 X 3 16 BALSA CROSS BRACES rij 1 8 xp My b x 3 8 BALSA FIN FRAME 1 i87 x 3 97 x DTP UT 1 8 BALSA LIZER SADDLE glue the fin frame together Note that there are two pieces along the bottom of the fin and that the TE ends at the bottom of the stabilizer 1 8 X 3 16 BALSA CROSS BRACES FROM 1 8 x 3 167 x Xy BALSA STCK 16 X 3 8 BALSA FIN FRAME FE hu s 18 X 3 4 X 30 BALSA STICK me CUT 1 8 BALSA MBILIZER SADDLE L1 4 From the 1 8 x 3 16 x 30 balsa stick cut and glue the fin cross braces to the frame 15 Remove the fin from your building board Inspect all the glue joints and
32. TRINGERS 20 48 ADJUSTABLE i ENGINE MOUNT DIE CUT 1 8 BALSA _ STABILIZER SADDLE DIE CUT 1 8 BALSA ALUMINUM ORWARD CENTER FUSE FCF SPINNER NUT q 4 3 AV a 1 8 X 3 8 BALSA a LONGERON COWL FRONT OUTER PUSHROD TUBE NYLON CLEVS DIE CUT 3 32 BALSA CLEMS RETAINER FUSELAGE LEFT SIDE VIEW STABILIZER SADDLE DOUBLER wee SHOWN WITH THE FUSELAGE LEFT 1 16 X 3 BALSA SIDE REMOVED FOR CLARITY BOTTOM SHEETING DIE CUT 3 16 BALSA RUDDER FRAME COWL BOTTOM ill DIE CUT 1 8 PLY EXHAUST EXIT SIDE EES DIE CUT 1 8 PLY FUSE STRUT MOUNTING PLATE LARGE NYLON 2 56 X 1 2 CONTROL HORN MACHINE SCREW YLON LANDING 1 4 X 1 4 BASSWOOD DIE CUT 3 32 BALSA DIE CUT 1 8 PLY GEAR STRAP 1 RAILS LOWER FUSELAGE DOUBLER LANDING GEAR RAIL SUPPORT 3 32 WHEEL COLLAR NOT INCLUDED 1 TAILWHEEL 2 X 3 8 SHEET DIE CUT 1 8 BALSA DIE CUT 3 16 BALSA 1 2 X 3 4 X 5 8 BASSWOOD METAL SCREW FORWARD LOWER FUSE FLF LEADING EDGE DOUBLER LANDING GEAR TORQUE BLOCK 1 8 X 3 16 BALSA DIE CUT 1 8 BALSA DIE CUT 3 16 BALSA CROSS BRACES LANDING GEAR COVER STABILIZER CENTER 3 16 X 3 8 BALSA STABILIZER FRAME ABS WHEEL PANT 1 2 X 3 4 X 4 13 16 BASSWOOD LANDING GEAR RAIL BEVEL THE CORNERS 5 32 MAIN LANDING GEAR FOR EASIER INSTALLATION 42 X 3 8 SH
33. USHROD PUSHROD TUBE PUSHROD TUBE F S3 NYLON CLEVIS 1 8 DOWEL STRINGERS 074 X 36 WIRE PUSHROD 4 4 DIE CUT 1 8 PLYWOOD AFT DECK BASE DIE CUT 1 8 PLY FUEL TANK TRAY 8 T BN E eor 3 8 X 3 4 x 1 3 8 wh FUSELAGE TOP VIEW e DIE CUT 3 32 BALSA DIE CUT 3 32 BALSA UPPER FUSELAGE DOUBLER DIE CUT 1 8 BALSA DIE CUT 3 32 BALSA UPPER FUSELAGE DOUBLER COVERING FILM DIE CUT 1 8 BALSA FORWARD TOP FUSE FTF UPPER FUSELAGE DOUBLER Du FORWARD TOP FUSE FTF g B 2 X 3 8 SHEET METAL SCREW IP VK OUTER PUSHROD TUBE 1 2 WASHER 1 4 X 1 4 BASSWOOD SERVO RAILS N 1 8 X 1 4 BALSA TOP STRINGER amp WINDOW FRAME DIE CUT 3 32 BALSA AFT FUSELAGE DOUBLER 1 8 DOWEL STRINGERS 2 X 3 8 SHEET METAL SCREW AC Lr n 1 8 X 3 8 BALSA LONGERONS 1 8 X 1 4 BALSA 1 8 X 1 4 BALSA TOP STRINGER amp TOP STRINGER WINDOW FRAME 1 16 X 3 BALSA TOP DECK SHEET DIE CUT 1 8 BALSA BM AFT FUSE SIDE AFS gt DIE CUT 1 8 PLYWOOD AFT DECK BASE THROTTLE PUSHROD EXIT LOCATION FOR A 4 STROKE ENGINE DIE CUT 1 8 BALSA FORWARD CENTER FUSE
34. WITH ALL WOOD CONSTRUCTION INSTRUCTION MANUAL WARRANTY Great Planes Model Manufacturing Co guarantees this kit to be free from defects in both material and workmanship at the date of purchase This warranty does not cover any component parts damaged by use or modification In no case shall Great Planes liability exceed the original cost of the purchased kit Further Great Planes reserves the right to change or modify this warranty without notice In that Great Planes has no control over the final assembly or material used for final assembly no liability shall be assumed nor accepted for any damage resulting from the 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 buyers are not prepared to accept the liability associated with the use of this product they are advised to return this kit immediately in new and unused condition to the place of purchase READ THROUGH THIS INSTRUCTION MANUAL FIRST IT CONTAINS IMPORTANT INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY MODEL MANUFACTURING COMPANY AND USE OF THIS MODEL 788 Urbana IL 61801 217 398 8970 productsupport greatplanes com TYL2P03 for GPMA0155 V1 1 Printed In USA Entire Contents Copyright 2009 TABLE OF CONTENTS SAFETY 2 INTRODUCTION 3 PREGCAUTIONS ub Bete
35. _1 1 Cut the spreader bar from the supplied Great Planes engine mount and trim off any flashing Slide the two halves together Make sure the do not bind L1 2 Temporarily mount the engine mount to the firewall with four 6 32 x 3 4 phillips head machine screws and 6 washers Note that the engine will be mounted with the cylinder head positioned at the lower right side Do not tighten the screws completely 2 Place your engine on the engine mount and adjust the mount until the engine fits between the mounting rails When the engine mount is adjusted tighten the mounting screws L1 4 Position the engine on the engine mount with the front of the engine drive washer 4 1 16 from the front of the firewall Carefully mark the engine mounting holes on the rails A great method for marking the engine mounting holes is to use the Great Planes Dead Center Engine Mount Hole Locator With the engine positioned on the mounting rails insert the self centering cone in the mounting hole Twist the shaft and the drill bit inside will mark the spot with a small starter hole 1 5 Remove the engine from the engine mount Drill a 3 32 diameter hole at each mark If you have access to a drill press it is the best tool for the job However if you are using a hand held electric drill try to keep the drill bit perpendicular to the rails LJ 6 Install the engine on the engine mount with four 4 x 5 8 sheet metal screws Hint The sheet
36. add CA to any joints that don t look strong Fill any gaps with balsa sanding dust and a drop or two of thin CA L1 6 Build the rudder frame from the die cut 3 16 balsa R 1 and R 2 frame pieces and leftover 3 16 x 3 8 balsa stick 7 1 87 X 3 16 BALSA CROSS BRACES t FROU t a x 3167 10 JASA STICK 3 16 X 3 8 BALSA RUDDER FRAME cut FROM 3 18 X 3 8 X 30 SALSA STCK TA 17 From the leftover 1 8 x 3 16 balsa stick cut and glue the rudder ribs and cross brace to the frame 18 Remove the rudder from your building board Inspect all the glue joints and add CA to any joints that don t look strong First sand both sides of the rudder and fin flat and even Then sand the rudder and fin to shape using the fuse plan as a guide Be careful that you don t sand any area too thin Build the Stabilizer amp Elevators L1 1 Cover the stabilizer elevator portion of the plan with waxed paper or Plan Protector 12 From one of the 3 16 x 3 8 x 30 balsa sticks cut the stabilizer trailing edge and trailing edge doubler to match the stabilizer plan Glue the TE doubler to the TE and pin them over the plan gt 3 8 X 3 8 BALSA ELEVATOR FRAME tow QW TEN L1 3 Pin the die cut 3 16 balsa leading edge doubler S 1 and stab center S 2 in position Glue S 2 to S 1 and to the front of the stab TE doubler C 1 67 X X Bh SA BOTIOM itf TiNG m P 9 o
37. and firewall With the sheet tight against the instrument panel and firewall trim the edge to the center of the top stringer LJ 5 Glue the top sheet to the instrument panel and firewall 16 Repeat steps 4 and 5 for the other top deck sheet half 28 _1 7 Trim and sand the forward edge of the top deck sheets flush with the front of the firewall and the aft edge to the instrument panel as shown Sand the fuse sides to blend into the top deck sheet L1 8 Test fit the 3 8 x 3 4 x 1 3 8 maple wing mounting blocks into the slots in the fuse top doublers former F 4 and the fuse sides sanding as necessary to provide a good fit When satisfied with the fit use epoxy to glue the wing mounting blocks to the fuse Sand the Fuselage a 1 Fill any small gaps in the fuselage with balsa filler L4 2 Use a sanding bar to sand the fuse sides and bottom smooth 213 Sand the lower corners of the landing gear rail and bottom sheeting to a slightly rounded shape as shown on the plan 1 4 Sand the wing saddle area slightly to remove any excess glue Mount the Wing to the Fuselage L1 1 Position the wing in the wing saddle and visually align it with the fuselage The center joint of the wing should align with the slot in former F 4 A A L1 2 Use a tape measure to measure the distance from the corner of the aileron bay to the center of the tail Then measure the distance from the other aileron bay and check if the dis
38. at http www modelaircraft org INTRODUCTION Since its introduction in the late 1930 s there have been 100 s if not 1000 s of the full size T Craft sold in the U S A They have come in many versions Some are very stable while others are very aerobatic like the clipped wing T Craft Great Planes has taken the aerobatic qualities of the full size Clipped Wing T Craft and designed them into this 20 sized scale model This plane loops rolls and flies knife edge but still has the stability of a high wing airplane So if you re ready for an easy building fun to fly airplane let s finish reading this introduction and start building While the T Craft 20 is easy to fly it does not have the total self recovery and stability of a basic trainer like the Great Planes series of PT basic trainers Therefore if you have never flown an R C airplane before we strongly recommend that you seek out the assistance of an experienced R C pilot who will be able to check out your construction and help you with your first flights On the other hand if you have already learned the basics of R C flying and you are able to safely handle a low wing airplane the T Craft 20 is an excellent choice to improve your flying skills Note We as the kit manufacturer provide you with a top quality kit and great instructions but ultimately the quality and flyability of your finished model depends on how you build it therefore we cannot in any way guarantee the p
39. b assemblies 4 Work on a flat surface Cover the plans with waxed paper or Great Planes Plan Protector to prevent glue from sticking to the plan 5 When instructed to test fit parts this means DO NOT USE GLUE until you are satisfied that everything fits properly THEN glue the parts together if instructed to do so 6 Whenever the instructions tell you to glue pieces together use CA When a specific type of glue is required the instructions will state the type of glue that is highly recommended When 30 minute epoxy is specified it is highly recommended that you use only 30 minute or slower epoxy because you will need either the working time and or the additional strength 7 The easiest way to cut balsa sticks is with a single edge razor blade or razor saw Position the stick over the plan mark its size then cut the part on a cutting mat A modeling miter box works well for cutting square corners and 45 degree gussets 152 4 mm 304 8 mm 457 2 mm 533 4 mm 609 6 mm 762 0 mm 914 4 mm 4 6 7 0 10 20 30 40 Metric Scale 50 60 70 80 90 100 110 120 130 140 150 160 170 180 DIE CUT PATTERNS TYL2F01 3 32 X 3 X 30 BALSA LANDING GEAR FAIRING 2 PER KIT LLY GY EY 7777277777 LLLI 272 TYL2F03 1 8 X 3 X 24 BALSA OUTER WING JOINER TYL2WO2 1 PER KIT 1 16 X 4 3 4 X 11 3 4 BALSA OUTER WING JOINER WHEEL PANT RETAINER WHEEL PA
40. be routed down the center of the fuse requiring the throttle servo to be mounted in the center of the servo rails If a 4 stroke engine is installed the throttle servo may need to be mounted next to the fuse side L1 12 With the servos centered and the control surfaces in neutral position use a felt tip pen to mark where the elevator and rudder pushrods cross the mounting holes in the servo arms Note The servo arms have been painted for clarity m L1 13 Disconnect the clevises from the control horns Make a 90 degree bend at the marks you made Temporarily install a nylon FasLink on each pushrod and cut the wire so it slightly protrudes out of the FasLink Hint If you prefer to bend and cut the pushrods out of the fuselage remove the clevis pull the pushrod out make the 90 degree bends at the marks and cut the rods Reinstall the pushrods in the guide tubes from the front and screw the clevises back on Note If necessary enlarge the holes in the servo arms with a 5 64 drill bit or a 48 drill for precision Install the Throttle Pushrod to roughen the outside of the 24 outer pushrod tube Insert the outer pushrod tube through the throttle pushrod exit hole in the firewall With the aft end of the outer pushrod tube approximately 1 1 2 from the throttle servo arm glue the outer pushrod tube to the firewall Cut the pushrod tube flush with the firewall L1 2 Thread the 2 56 x 1 stud into one end of
41. bration may cause your fuel to foam which will in turn cause your engine to run lean or quit We use a Flite Precision Magnetic Prop Balancer TOPQ5700 in the workshop and keep a Great Planes Fingertip Balancer GPMQ5000 in our flight box Find a Safe Place to Fl The best place to fly your T Craft is at an AMA chartered club field Ask the AMA or your local hobby shop dealer if there is a club in your area and join Club fields are set up for R C flying and that makes your outing safer and more enjoyable The AMA also can tell you the name of a club in your area We recommend that you join AMA and a local club so you can have a save place to fly and have insurance to cover you in case of a flying accident The AMA address and telephone number are in the front of this manual If a club and flying site are not available find a large grassy area at least 6 miles away from houses buildings and streets and any other R C radio operation like R C boats and R C cars A schoolyard may look inviting but is too close to people power lines and possible radio interference Ground Check the Model Inspect your radio installation and confirm that all the control surfaces respond correctly to the transmitter inputs The engine operation must also be checked by confirming that the engine idles reliably and transitions smoothly and rapidly to full power and maintains full power indefinitely The engine must be broken in on the ground
42. by running it for at least two tanks of fuel following the engine manufacturer s recommendations for break in Make sure all screws remain tight that the hinges are secure and that the prop is on tight Range Check Your Radio Whenever you go to the flying field check the operational range of the radio before the first flight of the day First make sure no one else is on your frequency channel With your transmitter on and the transmitter antenna collapsed you should be able to walk at least 100 feet away from the model and still have control While you work the controls have a helper stand by your model and tell you what the control surfaces are doing Repeat this test with the engine running at various speeds with a helper holding the model If the control surfaces are not always responding correctly do not fly Find and correct the problem first Look for loose servo connections or corrosion loose bolts that may cause vibration a defective on off switch low battery voltage or a defective receiver battery a damaged receiver antenna or a receiver crystal that may have been damaged from a previous crash If the radio appears to only be affected when the engine is running try moving your receiver and receiver antenna farther away from the engine Engine Safety Precautions Note Failure to follow these safety precautions may result in severe injury to yourself and others Keep all engine fuel in a safe place away from high heat
43. collar not included a 1 tail wheel not included and a second 3 32 wheel collar on the tailwheel wire Secure the wheel collars to the tailwheel wire with 4 40 set screws not included Use thread locking compound on the set screws to prevent them from loosening L1 2 Reinstall the landing gear on the fuse and the wheel and wheel pants on the landing gear Finish the Model L1 1 Cut one of the 64 rubber bands into six 3 4 long pieces Hold the landing gear fairing to the landing gear pull the rubber band straps around the landing gear and glue them to the covering on the bottom with thin CA The top forward rubber band strap goes over the landing gear and the aft strap attaches to the fuse L1 2 Reinstall the engine and cowl 1 Assemble the fuel tank per the manufacturer s instructions Connect approximately 1 of fuel tubing to the fuel pick up fitting on the fuel tank and 1 of fuel tubing to the pressure fitting on the tank Wrap the fuel tank in 1 4 foam rubber If you are installing the fuel tank so it can be removed use a vinyl tape to attach the fuel tank to the fuel tank tray As you insert the fuel tank into the fuel tank compartment route the fuel tubing out of the firewall If the tank is to be removable attach the fuel tank tray to former F 2 with two 2 x 3 8 screws Attach the proper fuel tubes to the engine and muffler L1 4 Lightly sand a strip approximately 1 8 wide along the inside of
44. die cut 1 8 plywood fuselage strut mounting plate to the inside of the fuselage floor at the location shown on the plan LE d METAL SCREWS X 11426 Drill a 1 16 hole in the center of both left wing strut mounting plates in the wing Attach the struts to the strut mounting plates with 2 x 3 8 sheet metal screws J 7 Lay the wing struts so that they are positioned across the fuselage at the fuselage strut mounting plate location Mark where the wing struts cross the edge of the fuselage Cut the wing struts off at the marks and check their fit A B g 2 11148 Position the unfinished end of the forward strut at the fuselage strut mounting plate With the aft strut positioned on top draw a line on the forward strut where the aft strut crosses it Remove the front strut and cut away the balsa behind the line you drew 441 9 Carefully cut a slit 1 2 deep in the end of the aft wing strut Install a 1 4 x 1 CA hinge in the slit and secure it to the wing strut with thin CA Center the CA hinge from the aft strut over the fuselage strut mounting plate on the fuselage Drill a 1 16 hole through the center of the CA hinge and the fuselage strut mounting plate Attach the strut to the fuselage with a 2 x 3 8 sheet metal screw L1 10 Reinstall the forward strut on the wing Test fit the forward wing strut against the aft strut Trim the forward strut as needed to achieve a good fit Glue the st
45. e in too far leaving only a small portion of the hinge in the control surface To avoid this you may insert a small pin through the center of each hinge before installing This pin will keep the hinge centered while you install the control surfaces ASSEMBLE THEN APPLY 6 DROPS OF THIN CA TO CENTER OF HINGE ON BOTH SIDES p 22 prm MV gt p dio se lt lt gt n P d 4 Insert the joiner wire through the fuse TE Glue the joiner wire in the elevator halves with 6 minute epoxy Before the epoxy cures apply 6 drops of thin CA adhesive to both sides of each hinge Allow a few seconds between drops for the CA to wick into the slot Use a paper towel to wipe off any excess CA that may have gotten onto the covering 5 Install the ailerons with their hinges repeating the gluing technique described previously _1 6 Wipe off the nylon tailwheel bearing with a paper towel dampened with rubbing alcohol Use 6 minute epoxy to glue the tailwheel bearing in the aft end of the fuse After the 43 epoxy has cured pack the tailwheel wire hole in the rudder with 6 minute epoxy Install the rudder with its hinges Repeat the gluing technique described previously and allow the epoxy to cure Hint Apply a little petroleum jelly to the tail gear wire where it passes through the nylon bearing This will prevent the wire from being glued to the bearing Install the Wheels 1 Install a 3 32 wheel
46. e left wing panel 114 Aileron LE followed by the bottom and top 5 Wing struts Painting Your Model After the model is covered use fuel proof model paint 30 minute epoxy thinned with alcohol or finishing resin to coat areas that may be exposed to raw fuel or exhaust residue such as the firewall wing saddle and fuel tank area Top Flite LustreKote is a high quality paint that is fuel proof and perfectly matches Top Flite MonoKote The paint is well suited to putting a high quality finish on ABS cowl and wheel pants but does have a tendency to curl materials such as styrene and butyrate windshield and side windows Do not paint the clear windshield with LustreKote directly from the can It can cause the plastic to curl We recommend Formula U for painting the clear windshield directly from the can or the following procedure can be used for successful results with LustreKote The following procedure allows you to airbrush LustreKote with good results The recommended procedure requires that the paint be sprayed into a jar or plastic mixing cup This is best done by spraying the paint through a small brass tube or straw into the jar For best results spray no more than oz of paint into the jar at a time As the propellant boils off it will cause the paint to foam slightly Leave the paint in the open container stirring every 15 minutes until no more foam appears on the surface of the paint and the paint has warmed
47. e on the LE of the aileron and the TE of the aileron bay Note The centerline is not centered at the tip of the aileron C 14 Cut the hinge slots in the aileron and the wing Cut three 3 4 wide hinges from the supplied hinge strip and trim the corners Insert the hinges in the aileron and fit the aileron to the wing Do no glue until told to do so L 15 Remove the aileron from the wing Mark the bevel to lines on both sides of the aileron 3 16 from the LE Shape the LE of the aileron to a V as shown on the plan L1 L1 16 Check the fit of the aileron on the wing The aileron should have 3 4 to 1 of throw each way L1 17 Return to step 1 of Assemble the Ailerons and build the second aileron Assemble amp Install the Wing Tips J L1 1 Cover the wing tip portion of the wing plan with waxed paper or Great Planes Plan Protector 1142 Assemble one wing tip from one of each of the die cut 1 8 balsa parts T 1 T 2 and T 3 There are two of each part one for each wing tip Position the wing tip parts over the plan and glue them together Fill any gaps with medium CA then sand smooth L1 3 Glue the wing tip perpendicular to rib W 6 The TE of the wing tip should be centered on the LE of the aileron The LE of the wing tip should be centered on the LE of the wing 1144 Glue the die cut 3 32 balsa wing tip support TS to W 6 the ends of the main spar and T 2 Sand the end of the tip support flush with
48. earning how the T Craft behaves in each Try to stay within a sensible and realistic scale like flight envelope If you feel as though you have your hands full keep this in mind pull back on the throttle stick to slow the model down This will make everything happen a little slower and allow yourself time to think and react Sometime well before it s time to land you should climb your T Craft to a safe altitude reduce the throttle and check out the model s low speed characteristics Do this a few times so you know what to expect upon landing and how the T Craft handles stalls When it is time to land fly a normal landing pattern and approach Keep a few clicks of power on until you are over the runway threshold Then reduce power and the T Craft will naturally bleed off speed Keep the nose down slightly then level off just before touchdown For your first few landings plan to land slightly faster than stall speed and on the main wheels Have a ball But always remember to think about your next move and plan each maneuver before you do it Impulsively jamming the sticks without any thought is what gets most fliers in trouble rather than lack of flying skill Happy Landings 2 View Use the 2 view or photocopy it and use the copy to design your trim scheme SCREW LOCK DIE CUT 1 8 PLY M PUSHROD CONNECTOR FUSE STRUT MOUNTING PLATE 074 X 1 THREADED ROD 074 X 6 WIRE OUTER NYLON INNER P
49. ed tube to carefully gouge the leading edge of the elevators You ll have to make several shallow passes to make the recess deep enough for the joiner wire 115 Temporarily join the elevators with the joiner wire The joiner wire will be easier to install if you chamfer bevel the ends a little If necessary tweak the joiner wire so the elevators are parallel and lay flat on your building table when the joiner wire is installed If you found it necessary to tweak the joiner wire use a felt tip pen to mark it so you can install the joiner wire in the same orientation when you permanently join the elevators L1 16 Lay the elevators and stab over the plan and lightly mark the hinge locations on the LE of the elevators and the TE of the stab Repeat the process to mark the hinge locations on the LE of the rudder and TE of the fin We have simplified the task of cutting hinge slots with the introduction of the Great Planes Slot Machine This electric tool easily cuts a perfect width slot for use with CA hinges every time L1 17 To cut the hinge slot place the blades onto the wood where you want the slot Lightly press the teeth into the wood When you are satisfied with the location press the button on the handle and the blades will cut easily into the balsa wood If you choose not to purchase a Slot Machine refer to the Expert Tip that follows to make hinge slots 10 MEE RYE Noe Wo Los
50. erformance of your completed model and no representations are expressed or implied as to the performance or safety of your completed model Please inspect all parts carefully before starting to build If any parts are missing broken or defective or if you have any questions about building or flying this airplane please give us a call at 217 398 8970 or e mail us at productsupport greatplanes com and we ll be glad to help If you are calling for replacement parts please reference the part numbers and have them ready when calling PRECAUTIONS 1 Build the plane according to the plans and instructions Do not alter or modify the model as doing so may result in an unsafe or unflyable model In a few cases the instructions may differ slightly from the photos In those instances the plans and written instructions should be considered as correct 2 lake time to build straight true and strong 3 Use an R C radio system that is in first class condition We highly recommend the use of micro servos on the ailerons and standard servos on the rudder elevator and throttle 4 You must properly install all R C and other components so that the model operates properly on the ground and in the air 5 You must test the operation of the model before every flight to insure that all equipment is operating and that the model has remained structurally sound Be sure to check clevises or other connectors often and replace them if they show
51. he airplane by gluing weight to the inside of the other wing tip Note An airplane that has been laterally balanced will track better in loops and other maneuvers 41 FINISHING Final Sandinq Fill any scuffs and dings with balsa filler or by expansion See Expert Tip below After the filler has dried use progressively finer grades of sandpaper to even and smooth all the edges seams and surfaces Sand a radius along the bottom edge of the fuse Remove all the balsa dust from the model with compressed air a tack cloth or a vacuum with a brush 2 We Many surface blemishes on a framed model are caused by bumps and balsa chips on the work surface This type of ding is best repaired by applying a drop or two of tap water to the blemish then running a hot sealing iron over the spot to expand the wood fibers After the surface has dried sand the expanded area smooth Cover the Model with MonoKote Film The T Craft does not require much painting to obtain the scheme shown on the box as most of the finish is done with Top Flite MonoKote covering The only painting required is the cowl windshield frame and wheel pants The technique we will describe here is how the model pictured on the box was finished Remove the engine landing gear windshield and control horns Cover the model with Top Flite MonoKote film using the sequence that follows The use of a Top Flite MonoKote Hot Sock on your covering iro
52. he pushrods with a paper towel dampened with rubbing alcohol to remove any oil left on the rods during manufacturing 16 Thread a nylon clevis approximately 14 turns onto one end of each pushrod Remove the backing plate from two large nylon control horns and connect the horns to the clevises in the outer hole 38 HINGE LINE CORRECT INCORRECT _1 7 Insert the pushrods into the outer pushrod tubes Position the control horns on the elevator and rudder as shown on the plans Mark the location of the control horn mounting holes and drill 3 32 holes at the marks Temporarily mount the control horns to the elevator and rudder with the backing plates and 2 56 x 1 2 machine screws _1 8 Mount the receiver switch on the side of the fuse We use a Great Planes Switch amp Charge Jack Mounting Set on all of our planes This allows you to check and charge the receiver battery without removing the wing L1 9 Wrap the receiver and receiver battery in 1 4 foam rubber L1 10 Temporarily position the receiver and receiver battery on the fuse bottom in front of former F 3 Later the receiver battery may be moved forward or aft to balance the plane Plug the receiver battery into the receiver switch 111 Mount the elevator rudder and throttle servos using the hardware that came with your radio on the 1 4 x 1 4 39 servo rail Note If a 2 stroke engine is being installed the throttle pushrod will possibly need to
53. hear webs to the aft side of the ply wing joiner between ribs W 2 and W 3 1 11 Sand the balsa sub LE flush with the top of the ribs L1 12 Support one wing panel with the wing tip crutch and weight the other panel flat on your building board On the weighted panel fit a 1 16 x 3 x 30 balsa sheet in place against the notch in the ribs and on top of the main spar and over one of the W 1A ribs Glue the balsa sheet to the main spar and notches When the glue has cured apply a bead of glue to the top of each rib along the sub LE and forward spar and joiner Pull the sheeting down making sure it contacts the surface of each rib sub LE and forward spar and joiner Hold it in place until the glue has cured 113 After the glue has cured switch the tip crutch to the other wing panel and repeat the sheeting process 14 Sheet the center section using a 1 16 x 3 x 30 balsa sheet L1 15 Trim and sand the sub LE top wing sheeting main spars and TE sheeting flush with the W 6 rib Trim the wing sheeting flush with the forward joiner 16 Sand the balsa sub LE flush with the bottom of the ribs and remove the bottom jig tabs from the bottom of all the ribs Note The sub LE tapers at rib W 6 117 Remove the crutch feet from the wing tip crutch and install them on the die cut 1 8 plywood center crutch CC L1 18 Position the wing upside down on your building board supported by the jig tabs on ribs W
54. iners into the left wing half checking the fit The main spars forward spars and TE on both wing halves should meet Make sure the left wing half is positioned on the tip crutch and the right wing half is flat against your building board Sight down the wing from the wing tip checking that the main spar sub LE and TE are straight If they are not lightly sand the ends of the spars or TE to achieve a straight wing Caution Remove only a small amount at a time You can always remove more wood but cannot add more wood once it s removed 7 When satisfied with the fit of the wing halves remove the joiners Use 30 minute epoxy to glue the two wing halves together Apply epoxy to the top and bottom of the center wing joiners the front and back sides of the main spars the front of the forward spars the ends of the forward joiner and the TE s Slide everything back together Wipe off any excess epoxy with a paper towel dampened with rubbing alcohol Check that the tip crutch is in position the right wing panel is flat against your building board and the main spar is straight Use clamps to hold the joiners in position until the epoxy cures L1 8 Glue together the two die cut 1 8 plywood ribs W 1A and the two die cut 3 32 balsa ribs W 1B 15 _1 9 Use epoxy to glue the W 1A ribs to the forward spars and forward joiner centered on the ply wing joiner Glue W 1B centered on the ply wing joiner and the TE 1 10 Glue s
55. it will be glued to the stab and fuse BUILD THE WING Build the Wing Panels Start by building the right wing panel right side up over the right wing panel plan so your progress matches the photos TWO WARPED SPARS INSTALLED THIS WAY WILL RESULT IN A STRAIGHT WING TWO WARPED SPARS INSTALLED THIS WAY WILL RESULT IN A WARPED WING Te ae 11 Match the six 1 8 1 4 x 30 basswood main spars so any warps will counteract each other 11 L1 2 Cut two of the main spars in half Draw a line 1 from one end of each of the 15 half spars and bevel the end of the spars to the line L Use epoxy to glue the four 15 main spars onto the four 30 main spars as shown on the plans Make sure the sides and ends of the spars are flush with each other Wipe off any excess epoxy before it cures 11144 Cover the wing panel plan with waxed paper or Great Planes Plan Protector 1 16 X 1 2 X 24 BALSA WING TE SHEETING TYL2WI1 5 Position one of the main spars over the plan aligning the double spar end of the main spar with the outboard edge of the root rib W 1 Mark the spar at the tip side of ribs W 4 1 8 X 1 4 MAIN SPAR 2 6 Cut a V notch part way through the spar at the mark so that the spar can bend at W 4 7 From one of the 1 16 x 3 x 30 balsa sheets cut four 1 2 x 3 4 shims Place the shims over the spar location on the plan starting between ribs W 2 and W 3 and
56. iver switch Important Slide the silicone clevis retainers over all the clevises before connecting the clevises to the control horns L1 2 Make a strain relief from a cut off servo arm and place it on the antenna where the antenna exits the fuse Route the receiver antenna out of the fuse Anchor the antenna to the top of the fin with a rubber band and T pin Note Do not shorten the antenna Leave any excess trailing behind the model 44 BALANCE YOUR MODEL Note This section is VERY important and must NOT be omitted A model that is not properly balanced will be unstable and possibly unflyable 11 Accurately mark the balance point on the bottom of the wing on both sides of the fuselage The Great Planes C G Machine Airplane Balancer makes balancing your plane easy and exact The balance point C G is shown on the fuse plan and is located 3 back from the leading edge of the wing This is the balance point at which your model should balance for your first flights After initial trim flights and when you become more acquainted with your T Craft you may wish to experiment by shifting the balance up to 1 4 forward or backward to change its flying characteristics Moving the balance forward may improve the smoothness and stability but the model may then require more speed for takeoff and may become more difficult to slow down for landing Moving the balance aft makes the model more agile with a lighter snappier feel In
57. l turn after takeoff away from the pit or spectator areas and will not thereafter fly over pit or spectator areas unless beyond my control 4 will operate my model using only radio control frequencies currently allowed by the Federal Communications Commission FLYING Caution THIS APPLIES TO ALL R C AIRPLANES If while flying you notice any unusual sounds such as a low pitched buzz this may indicate control surface flutter Because flutter can quickly destroy components or your airplane any time you detect flutter you must immediately cut the throttle and land the airplane Check all servo grommets for deterioration this may indicate which surface fluttered and make sure all pushrod linkages are slop free If it fluttered once it will probably flutter again under similar circumstances unless you can eliminate the slop or flexing in the linkages Here are some things which can result in flutter Excessive hinge gap Not mounting control horns solidly Sloppy fit of clevis pin in horn elasticity present in flexible plastic pushrods Side play of pushrod in guide tube caused by tight bends Sloppy fit of control rods in servo horns Insufficient glue used when gluing in torque rods Excessive flexing of aileron caused by using too soft balsa Excessive play or backlash in servo gears and insecure servo mounting The Great Planes T Craft is a great flying plane that flies smoothly and predictably The T Craf
58. lves is a lip that the front cowl is glued over L1 2 Tape the top and bottom cowl halves together Wick thin CA along the joints Then reinforce the joint by gluing leftover ABS along the inside of the joints L1 Tape the front of the cowl to the top and bottom cowl halves and wick CA along the joint L1 4 Use a sharp hobby knife or Dremel MultiPro with a sanding drum to accurately trim the openings in the front of the cowl 15 Use coarse sandpaper to thoroughly scuff the inside of the cowl along all the seams Use 30 minute epoxy to glue strips of fiberglass cloth over the joints on the inside of the cowl L1 6 If you have removed the engine reinstall it Use a piece of thin cardboard or plastic as a template to locate the cowl for the head of the engine muffler needle valve and any other accessories that may protrude from the cowl example fuel fill valve engine choke etc Tape the template to the fuselage side accurately indicating the position of the accessories 36 _1 7 Measure the distance from the front of the firewall to the front of the drive washer on the engine Remove the engine from the engine mount and position the cowl on the front of the fuselage so that the forward edge of the cowl is 1 8 aft of the measurement you just made Use a felt tip marker to transfer the location of the engine and accessories onto the outside of the cowl 18 Remove the cowl and template and mount the
59. metal screw will be easier to install if you wipe the threads across a bar of soap before installing them 27 2 STROKE THROTTLE PUSHROD L1 7 Mark the location for the throttle pushrod exit fuel pick up line and fuel tank pressure line The best location for the throttle pushrod exit when installing an O S 2 stroke engine is centered just above the exhaust exit top For the four stroke engine the upper left corner will work A good location for the fuel pick up and pressure line exits are through the middle of the engine mount L1 8 Drill a 3 16 hole at the mark for the throttle pushrod exit If a 2 stroke engine is being installed and the throttle pushrod may need to be routed under the fuel tank tray drill a 3 16 hole through former F 2 centered under the fuel tank tray Drill 7 32 holes for the fuel and pressure line Sheet the Front Deck 11 Glue the die cut 3 32 balsa instrument panel IP perpendicular to the top of the front deck 12 From a remaining 1 8 x 1 4 balsa stick glue a top stringer between the firewall and the instrument panel e ah 3 From the remaining 1 16 x 3 balsa sheet cut two forward top deck sheets 4 1 4 long Sand a slight angle on one of the long edges and glue it flush with the cabin frame at the aft end and angled toward the firewall L 4 Wet the outside of the forward top deck sheet with warm water Carefully bend the sheet around the instrument panel
60. n will prevent scratching the MonokKote film Before you cover the fuselage first apply 1 4 wide strips of white Monokote film in the corners where the stab and fin meet the fuselage Proceed to cover the stab with pre cut pieces that meet in the corners and overlap the 1 4 strips Do not under any circumstances attempt to cut the covering on the stab after it has been applied except around the leading and trailing edges and the tips Modelers who do this may cut through the covering and into the stab This will weaken the structure to a point where it may fail during flight Some modelers prefer to cover the top and bottom of the ailerons with one strip of MonoKote film This is done by covering the bottom first then wrapping the Monokote film up over the leading edge We used Top Flite MonoKote White TOPQ0204 and True Red TOPQ0227 to cover our T Craft Suggested Covering Sequence Fuselage and Tail L1 1 1 4 strips at fin and stab as described 12 Fin TE followed by stab TE L1 Fuselage bottom Fuselage right side Fuselage left side Fuselage top Stab bottom followed by top Fin left side followed by the right side Elevator LE L1 10 Elevator bottoms followed by the top 1111 Rudder LE right side followed by the left side L1 12 Die cut 1 8 balsa Landing gear fairings Wing L1 1 Trailing edges of wing L1 2 Bottom right followed by the left wing panel L1 Top right followed by th
61. nd glue firewall reinforcements in the joint between the firewall and fuselage sides and the firewall and front deck 25 1 4 x 1 4 x 1 2 BASSWOOD STICKS L1 17 Temporarily install the die cut 1 8 plywood fuel tank tray Note that the front of the tank tray is angled to match the right thrust of the firewall The fuel tank tray may be permanently glued to the firewall and former F 2 at this time or two 1 2 long sticks may be cut from the remaining 1 4 x 1 4 basswood stick and glued to the aft edge of former F 2 flush with the bottom of the fuel tank tray Do not glue the tank tray to the 1 2 sticks The tank tray can then be installed with two 2 x 3 8 sheet metal screws threaded into the 1 2 sticks L1 18 Use epoxy to glue the 1 2 x 5 8 x 3 4 basswood torque blocks to the bottom of the 1 2 x 3 4 x 4 13 16 basswood landing gear rail L1 19 Use epoxy to glue the landing gear rail to the front of former F 2 the fuse sides and the landing gear supports Make sure the landing gear rail protrudes 1 16 above the bottom of F 2 This will allow the 1 16 balsa bottom sheeting to butt up against the side of the landing gear rail L1 20 Fit and glue the die cut 1 8 plywood exhaust exit side EES exhaust exit top EET and exhaust exit back EEB on the back of the firewall L1 21 From a leftover 1 8 x 3 8 balsa stick cut and glue a bottom sheeting support between formers F 4 and F 5 26
62. own Elevator Rudder Ailerons Note If your radio does not have dual rates we recommend setting the throws between the low and high rate amount Note The balance and control throws for the T Craft have been extensively tested This chart indicates the settings at which the T Craft flies best Please set up your model to the specifications listed above If after you become comfortable with your T Craft you would like to adjust the throws to suit your tastes that s fine Too much throw can make the plane harder to handle or force it into a stall or snap roll so remember more is not always better PREFLIGHT At this time check all connections including servo horn screws clevises servo cords and extensions Make sure you have installed the nylon retainer on the Screw Lock Pushrod Connector on the throttle pushrod and the silicone retainers on all the clevises Charge the Radio Batteries Follow the battery charging procedures in your radio instruction manual You should always charge your transmitter and receiver batteries the night before you go flying and at other times as recommended by the radio manufacturer Balance the Propeller Carefully balance your propellers before flying An unbalanced prop is the single most significant cause of vibration Not only may the engine mounting screws vibrate loose possibly with disastrous effect but vibration may also damage your radio receiver and battery Vi
63. r to cover and enhance the scale appearance 5 From a leftover piece of 3 16 balsa cut a fillet to fit between the fin LE and the top dowel stringer Glue it in place and sand the top edge to a rounded shape to blend in to the fin LE 16 From leftover 1 8 balsa make gussets to fit at the joint between the outside dowel stringers and former F 4 Mount the Landing Gear L1 1 Turn the fuse upside down On one end of the landing gear rail place in the groove a mark 3 8 in from the fuse side and 3 32 aft from the forward edge of the landing gear slot At the other end of the rail place a mark 3 8 in from the fuse side and 3 32 forward of the aft edge of the slot 12 At both marks drill 5 32 diameter hole through the landing gear rail and torque rod block perpendicular to the rail Insert the 5 32 main landing gear in the slot of the landing gear rail 1 4 Position the two nylon landing gear straps over the main landing gear as shown on the plan Mark the screw hole locations on the landing gear plate 5 Drill a 1 16 diameter pilot hole at each mark 33 vy RT 5 5 SM 1521 P p un A PA L1 6 Temporarily secure the main landing gear to the landing gear rail with the landing gear straps and four 2 x 3 8 screws Assemble the Wheel Pants L1 L1 1 Trim one matching set of wheel pant halves along the molded cut lines You can use a hobby knife to carefully
64. ruts together with thick CA 114111 Apply balsa filler in the joint between the two struts to blend them together L1 12 Repeat the process to assemble the wing struts the other side Note You may leave the struts permanently attached to the wing When you remove the wing from the fuse just remove the two screws which attach the struts to the fuse For storage the struts may be folded down onto the wing and held in place with rubber bands RADIO INSTALLATION Mount the Servos _1 1 Prepare the servos by installing the rubber grommets and brass eyelets into each servo _J 2 From the leftover 1 4 x 1 4 x 24 basswood stick cut two servo rails to fit in the notches in the lower fuse doubler Glue the forward servo rail in the notches in the lower fuse doubler and to the back of former F 3 Use the servos to position the aft servo rail and glue it to the lower fuse doublers From the 11 3 4 white nylon inner pushrod cut eight 1 8 long bushings 14 Cut the two 2 56 x 36 pushrods so that they are 24 long measured from the threaded end 5 Slide four bushings evenly spaced onto each pushrod Adjust the bushings nearest the ends of the rods so they will not interfere with the ends of the outer pushrod tubes and possibly become jammed during flight If the bushings slide onto the rods without much resistance use a drop of thin CA to hold them in position Hint Before installing the bushings wipe off t
65. s HCAR3780 1 Debonder GPMR6039 1 Clevis installation tool GPMR8030 1 Hot Sock TOPR2175 L1 Curved Tip canopy scissors HCARO0667 L1 Top Flite Precision Magnetic Prop Balancer TOPQ5700 Slot Machine motorized hinge slotting tool GPMR4010 e QUE EL ET P S WHEL We On our workbench we have three 11 Great Planes Easy Touch Bar Sanders equipped with 80 150 and 220 grit sandpaper This setup is all that is required for almost any sanding task We also keep some 320 grit wet or dry sandpaper handy for finish sanding before covering j Gute Great Planes Easy Touch Bar Sanders are made from lightweight extruded aluminum and can be found at most hobby shops They are available in five sizes 5 1 2 GPMR6169 for those tight hard to reach spots 11 GPMR6170 for most general purpose sanding and 22 GPMR6172 33 GPMR6174 and 44 GPMR6176 for long surfaces such as wing leading edges The Easy Touch Adhesive Backed Sandpaper comes in 2 x 12 rolls of 80 grit GPMR6180 150 grit GPMR6183 and 220 grit GPMR6185 and an assortment of 5 1 2 long strips GPMR6189 for the short bar sander The adhesive backed sandpaper is easy to apply and remove from your sanding bar when it s time for replacement This setup is all that is required for almost any sanding task Custom sanding blocks can be made from balsa or hardwood blocks and dowels for sanding difficult
66. signs of wear or fatigue Remember Take your time and follow the directions to end up with a well built model that is straight and true DECISIONS YOU MUST MAKE ENGINE SELECTION Recommended engine size 25 to 32 cu in 2 stroke 26 to 30 cu in 4 stroke Your Great Planes T Craft 20 will perform well with any of the engines within the recommended range PREPARATIONS Required Accessories Items in parentheses GPMQ4243 are suggested part numbers recognized by most distributors and hobby shops and are listed for your ordering convenience GPM is the Great Planes brand TOP is the Top Flite brand HCA is the Hobbico brand and COV is the Coverite brand L1 4 Channel radio with standard servos and 2 micro servos L1 2 24 extension for aileron servos HCAM2200 1 Y Harness for aileron servos HCAM2500 1 Engine See Engine Selection above L Propeller Top Flite Power Point Refer to your engine s instructions for proper size L Fuelproof paint see Painting section Medium fuel tubing 2 GPMQ4131 1 4 Latex foam rubber padding HCAQ1000 6 oz Fuel tank GPMQ4102 L Easy Fueler fuel filling valve GPMQ4160 Ly 2 2 1 2 Wheels GPMQ4223 L1 1 1 Tail wheel GPMQ4241 LI 2 3 32 Wheel collars GPMQ4302 4 5 32 Wheel collar GPMQ4306 L1 Pilot Williams Bros 18400 1 6 scale sportsman pilot used in prototype L 2 Rolls covering film J Aluminum spinner nut GPMQ4630
67. t The Landing 33 Assemble The Wheel Pants 33 Assemble The 35 Construct The Wing Struts 37 RADIO 38 Mount The 38 Install The Throttle Pushrod 40 Install The Pushrods 40 BALANCE THE AIRPLANE LATERALLY 41 FINISHING 22 as ya EX ARAS ERR RENE 41 mini wr 41 Cover The Model With MonoKote Film 41 Painting Your Model 42 FINAL HOOKUPS AND CHECKS 42 Install The Hinges 42 Install The 43 Finish The Model 2 39 Does tae Res 43 Reinstall The Radio 44 BALANCE YOUR MODEL 44 SET THE CONTROL THROWS 45 us tye vua D Dag ae eee dn 45 Charge The Radio Batteries 45 Balance The Propeller 45 Find a Safe Place to 46 Ground Check The Model 46 Range Check Your 46 Engine Safety 46 AMA SAFETY 46 46 Rado Controle
68. t does not however possess the self recovery characteristics of a primary R C trainer and should only be flown by experienced R C pilots Takeoff Takeoff on high rates if you have dual rates on your transmitter especially if you are taking off into a crosswind For all models it is good practice to gain as much speed as the length of the runway will permit before lifting off This will give you a safety margin in case the engine quits As the plane accelerates the tail will begin to lift and the plane will 47 turn left a characteristic of all taildraggers Be ready for this and correct by applying sufficient right rudder to hold the plane straight down the runway The left turning tendency will go away as soon as the tail is up and the plane s speed increases Be sure to allow the tail to come up Do not hold the tail on the ground with up elevator as the T Craft will become airborne prematurely and possibly stall For all models it is good practice to gain as much speed as the length of the runway will permit before lifting off When the plane has gained enough flying speed to safely lift off gradually and smoothly apply up elevator and allow the model to climb at a shallow angle do not yank the model off the ground into a steep climb Flight We recommend that you take it easy with your T Craft for the first several flights gradually getting acquainted with this great model Add and practice one maneuver at a time l
69. t fit the tailgear wire in the rudder L1 7 Cut a slot in the aft edge of the fuse at the marks you made for the tailgear bearing and the lower hinge Without using any glue join the rudder to the fuse L1 8 Trim the clear windshield along the embossed cut lines Then tape it in position on the front of the cabin 31 We T ue L1 9 With the wing installed note the gap between the LE of the wing and the windshield Install shims made from 1 8 balsa leftover from the die sheets to reduce the gap to approximately 1 32 on each side Install the Dowel Stringers A L1 1 Glue the die cut 1 8 balsa former F 5A perpendicular to the top of the aft deck LJ 2 Position one of the 1 8 diameter dowels in the center notch of F 4 and F 5A Sand the aft end of the dowel at an angle to match the angle of the fin LE Glue the dowel in place so that it is flush with the top of the stab Then cut off the forward end of the dowel flush with the front of F 4 In a similar manner cut and glue the two 1 8 side dowels in position The aft end of the dowels should be flush with the top of the stab and aligned with the fuse sides L1 4 From leftover 1 8 balsa fit and glue filler pieces between the dowel stringers and fin and the dowel stringers 32 and aft deck base Apply balsa filler to any gaps and sand smooth The purpose of these pieces is to make the fuse easie
70. tances are the same Adjust the wing until both distances are equal When the wing is perfectly aligned make reference marks on the wing trailing edge and former F 4 to help keep the parts aligned during the next step Tape the wing in position so that it cannot move Use a 13 64 or 10 drill bit to drill a hole through the wing at the two punch marks on the wing bolt plate Two small 90 degree triangles will help you to align the drill perpendicular to the top surface of the wing Important Do not allow the wing to shift during this procedure 14 Remove the wing and use a 1 4 drill bit to enlarge the holes in the wing only 29 L1 5 Use a 1 4 20 tap to cut threads into the wing bolt blocks After cutting the threads put a couple of drops of thin CA on the threads in the wing bolt block Allow the CA to cure before threading the tap back through the holes to clean up the threads Bolt the wing to the fuse with two nylon 1 4 20 wing bolts checking the fit Mount the Stabilizer amp Fin L1 1 To aid in alignment draw an accurate centerline on one side of the stabilizer This centerline should be in the middle of S 2 and perpendicular to the TE A A 2 With the wing mounted on the fuse center the stabilizer on the stab saddle aligning the centerline of the stab with the centerline of the fuse and the notch in the LE of the stab with the notch at the aft end of the aft deck base Align the
71. the windshield around the perimeter Note To avoid sanding more than you want it is helpful to first apply strips of masking tape on the inside of the windshield 1 8 in from the edge 15 Hold the windshield in place on the fuselage Use a fine tip marker to trace the outline of the windshield onto the covering Remove the windshield and use a sharp 11 blade to cut a 1 8 strip from the covering just inside the line you drew A sharp blade is important so you do not have to use much pressure It will allow you to cut only the covering and not the underlying wood L1 6 Carefully glue the windshield in place with a canopy glue such as Pacer Formula 560 Canopy Glue We do not recommend CA as it may fog the plastic Use masking tape to hold it in place while the glue dries _1 7 The side windows are cut from the 4 x 4 butyrate sheet Trim the windows to fit along the inside of the cabin side After the windows have been trimmed to fit glue them in place with a glue compatible with butyrate 8 The T Craft kit contains a decal sheet including the small emblems and the checkerboard on the tail which would be difficult to reproduce otherwise These decals are the peel and stick type Cut around the individual decal emblems peel off the protective backing and apply them to your airplane Reinstall the Radio System L1 1 Reinstall the rudder and elevator control horns pushrods receiver receiver battery servos and rece
72. to both sides of the aileron base perpendicular to the base _J L1 5 Trim the ends of the aileron LE flush with the aileron base 1116 From a leftover piece of 1 16 sheeting cut and glue a root rib to the root of the aileron MEO Hi AASIAA ERAT ERI 7 liga 1 TOOL n 1 mim gll JOHNSO Levelt amp i nu PO DERIT n ed A 7 Place a piece of leftover 1 16 balsa between the root rib of the aileron and the outside W 3 rib Use a straightedge to align the TE of the wing with the TE of the aileron Then securely pin the aileron to the wing L1 8 Use a razor plane and sanding bar to shape the aileron ribs and LE to shape 1149 From the leftover 1 4 x 1 4 balsa stick cut and glue an aileron LE doubler behind the aileron LE between the ribs that are in line with the aileron servo tray AILERON HORN 1 4 x 1 4 LE DOUBLER 114210 Position the die cut 1 8 plywood aileron horn base on the aileron LE and LE doubler Mark the outline of the base on the LE and doubler A 11 Mark the location of the hinges on the aileron and wing 112 12 Remove the aileron from the wing and trim the aileron LE and LE doubler to recess the aileron horn base flush with the top of the aileron ribs and LE When satisfied 19 with the fit glue the aileron horn base to the LE LE doubler and aileron rib J L1 13 Draw a centerlin
73. to reach spots Common Abbreviations Fuse Fuselage LE Leading Edge front TE Trailing Edge rear Stab Stabilizer Inches Elev Elevator LG Landing Gear Ply Plywood Types of Wood IMPORTANT BUILDING NOTES 1 Unroll the plan sheets then re roll the plans inside out to make them lie flat 2 Sort through the sticks and sheets grouping them by size Masking tape can be used to bundle matching sheets and sticks Using a felt tip or ballpoint pen lightly write the part name or size on each piece or bundle Refer to the parts list and plans for sizes and quantities Use the die cut patterns shown on page 6 to identify the die cut parts and mark them before removing them from the die sheet Save all leftovers If any of the die cut parts are difficult to remove do not force them Instead cut around the parts with a hobby knife or lightly sand the back of the sheet After removing the die cut parts use your sanding block to lightly sand the edges to remove any die cutting irregularities 3 As you identify and mark the parts separate them into groups such as fuse fuselage wing fin stab stabilizer and hardware Metric Conversions 1 64 4 mm 1 32 8 mm 1 16 1 6 mm 3 32 2 4 mm 1 8 3 2 mm 5 32 4 0 mm 3 16 4 8 mm Inch Scale 0 1 2 3 2 SANE We Zipper top food storage bags are handy to store the small parts as you sort identify and separate them into su
74. top the engine Do not throw anything into the prop of a running engine AMA SAFETY CODE EXCERPT Read and abide by the following Academy of Model Aeronautics Official Safety Code 1 will not fly my model aircraft in sanctioned events air shows or model flying demonstrations until it has been proven to be airworthy by having been previously successfully flight tested 2 will not fly my model aircraft higher than approximately 400 feet within 3 miles of an airport without notifying the airport operator will give 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 aircraft 3 Where established will abide by the safely rules for the flying site use and will not willfully and deliberately fly my models in a careless reckless and or dangerous manner 7 will not fly my model unless it is identified with my name and address or AMA number on or in the model 9 will not operate models with pyrotechnics any device that explodes burns or propels a projectile or any kind Radio Control 1 I will have completed a successful radio equipment ground check before the first flight of a new or repaired model 2 will not fly my model aircraft in the presence of spectators until become a qualified flier unless assisted by an experienced helper 3 will perform my initia
75. two screws holding the nylon landing gear strap on the wheel pant Slide the wheel pant partially off of the landing gear Slide a 5 32 wheel collar a 2 1 2 wheel followed by a second 5 32 wheel collar onto the landing gear Reinstall the wheel pant to the landing gear with the nylon landing gear strap Refer to the fuse plan for a detailed view of the wheel pant assembly 414 13 Adjust and tighten the wheel collars on the landing gear so that the wheel rotates freely L1 14 Return to step 1 of Assemble the Wheel Pants and assemble the other wheel pant 35 L1 15 Before painting the wheel pants fill the seams with a filler such as Bondo Auto Body Filler or an automotive scratch and dent glazing compound We use Bondo most of the time as it cures quickly and sands easily but it is normally sold in large quantities Automotive glazing compound usually comes in small tubes dries quickly and sands easily but for proper drying can only be applied in thin layers 1 16 After the filler cures wet sand the wheel pants with 400 grit sandpaper to prepare them for primer Assemble the Cowl _1 1 The cowl is assembled the same as the wheel pants Cut the cowl along the cut lines use a bar sander to true the edges Roughly cut out the openings in the front of the cowl and roughen the inside of the cowl along all the seams Note The top and bottom cowl halves use a butt joint to join the two halves On the front of the two ha
76. y knife or a Dremel Multipro with a sanding drum to finish cutting the wheel openings Hint Make the wheel openings as wide as possible This will make installing the wheels and axles easier and cause less interference with the wheels upon landing and taking off 114298 Drill a 5 32 hole in the wheel pant at the bottom of the slot for the landing gear wire 1119 Slide the wheel pant over the landing gear wire so that the wire is recessed into the slot in the wheel pant Center a nylon landing gear strap centered over the slot in the wheel pant Mark the mounting holes remove the strap and drill a 1 16 pilot hole at both marks LJ L1 10 Drill a 5 32 hole in the center of the die cut 1 8 plywood wheel pant retainer Slide the die cut 1 8 plywood wheel pant retainer over the landing gear Then securely attach the wheel pant to the landing gear with the nylon landing gear strap and two 2 x 3 8 sheet metal screws E 11411 Adjust the position of the wheel pant so that the axle part of the landing gear is perpendicular to the centerline of the wheel pant Stand back a few feet from the plane and view the wheel pant from the front and side making sure it is positioned correctly When satisfied with the position use epoxy to glue the wheel pant retainer to the side of the wheel pant By using epoxy to glue the retainer on you can re adjust the position of the wheel pant before the glue cures L1 12 Remove the

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