aero naut Order No.
PEPPER is a sleek model with a considerable speed range. Building materials are mostly laser-cut balsa and light-ply to achieve a light yet strong structure, spruce is used to enhance the strength of the wing spars. For electric power choose a 28 mm brushless motor with a power of about 200 W. They all have a bolt circle diameter of 19/16 which will fit the model´s motor mount. Construction should be according to the step-by-step instructions provided in this manual.
1 In a first step glue together main spar parts F1 A and F1 B. Use a straight edge against the spar´s building tabs for proper alignment and secure with tape. Assemble the 4-part wing jig, place on a flat building board and secure with tape. F1 B F1 A F14 F13 F12 F11 F10 2 Insert main spar in wing jig. Glue together centre ribs F2, then glue ribs F2 to F14 to main spar as shown. Make sure that ribs are fully seated in main spar and jig.
3 At one end only splice leading edge F15 (4×4 mm obechi) and both spruce spars F16 (5×2 mm spruce) over a length of ca. 15 mm. Leading edge and spars must have a length of 1,110 and 1,150 mm, respectively. F15 F16 Fit and glue in place upper spar F16. Glue leading edge F15 to front of ribs and secure with pins inserted in wing jig just in front of leading edge. Slightly chamfer contact surface of both auxiliary spars F17 at centre ribs and glue to rear end of ribs.
Glue together upper (F19 + F20) and lower (F21 + F22) wing sheeting and place on a flat surface. Immediately remove any excessive glue and secure with tape until dry. F21 F19 F22 F20 6 Glue in place upper wing sheeting of each wing half in two steps. Slightly chamfer front edge of upper wing sheeting for proper fit at leading edge. Apply glue to contact surface of leading edge and the first 5 mm of ribs. Fit upper wing sheeting in place on leading edge and secure with tape. Leave to dry.
7 8 Remove wing from jig and turn upside down. Break off building tabs and sand lightly to achieve a smooth contact surface on main spar and ribs. Glue in place lower spruce spar F16 and servo frames F23. F16 From trailing edge triangular stock (8×40 mm) cut off two ca. 25 mm long pieces F24, then fit and glue in place next to centre ribs as shown.
9 Install servo leads in wing and secure with tape in servo bay. Route opposite end of servo leads through hole in lower wing sheeting and glue wing sheeting in place. Use same proceedrue as with upper wing sheeting. 10 Carefully sand flush rear edge of wing. Cut off one ca. 80 mm long piece of either trailing edge triangular stock F25 (8×30 mm) and glue to wing tip as shown. Make sure that projection of end rib meets with rear edge of trailing edge profile. See also following building step.
11 Cut off spars, leading and trailing edges at end ribs and carefully sand flush with contact surfaces of end ribs. Glue in place wing tips F26 (balsa triangular stock, 20×20 mm) on end rib and secure with pins. F26 12 i When dry, sand wing tips and leading edge to shape and give wing a smooth surface. Note: Wing tips are shaped automatically when upper and lower wing sheeting are sanded to a smooth finish with a sanding bar. Finally lightly chamfer edges of wing tips.
13 Glue together aileron servo mounts from 4 pieces F27 each. Align servo with servo arm centred in slot of servo tray F28, hold in place and glue servo mounts in place with a drop of medium CA. F27 Insert servo in servo mounts and install servo tray in wing. Drill servo frame F23 with 1.5 mm and temporarily install screws F31. i Note: Servo is held in place by servo mounts. No glue required.
15 Glue former R5 at right angles into servo tray R4 and glue former R8 at right angles into R7. R4 16 Check with set square or similar. Glue servo tray into former R3 at right angles. R8 R5 R7 R3 17 R3, R4, R5 Place right fuselage side R1 A on flat building board and secure with pins. R12 Insert former R2 and assembly R3, R4, R5 in fuselage side. Do not glue! Glue in place wing saddle R12 and make sure contour matches contour of fuselage side perfectly. Remove any excessive glue from slot in R12.
18 Glue reinforcements for tailplane slot R13 and R14 to fuselage side. Temporarily insert former R11 into fuselage side as an end stop. R13 R11 R14 19 Cut off two 375 mm and two 225 mm long pieces of 8×8 mm triangular stock R15. Place triangular stock on building board as shown and use a razor saw to make cuts at intervals of 15 to 20 mm over a length of 200 mm. This will make the triangular stock easier to bend when you glue it to the fuselage side.
20 Glue triangular stock R15 on fuselage side along top and bottom contours as shown and secure with pins. i Note: Bottom strip ends in front of former R3. R3 R15 R15 R11 21 Cut to length four pieces of 6×6 mm triangular stock R16 for top and bottom rear fuselage contours. R10 R9 Temporarily insert formers R9 and R10 into right fuselage side, glue triangular stock in place and secure with pins. R16 Remove formers R9, R10, R11.
22 Glue in place canopy frame R17 on fuselage side along canopy cut-out. Remove any formers/assemblies from right fuselage side and build up left fuselage side R1 B accordingly. R17 R3, R4, R5 23 Glue former R2 as well as assembly R3, R4, R5 in place on right fuselage side. i R6 Note: R2 is at right angles on fuselage side. Glue in place battery tray R6, insert and glue wing retainer R18 in slot in R12.
24 Make sure that left fuselage side R1 B fits perfectly on formers R1 B before you glue. Make corrections as necessary. Then glue in place left fuselage side on formers and glue R19 onto wing retainer R18. R19 R18 25 Glue former R11 into rear of fuselage (bore for elevator control faces up), glue together rear end of fuselage sides without sanding reinforcements R13, R14. Secure with clamps. i Note: Width at rear end of fuselage must not be reduced. Elevator control exits between fuselage sides.
26 Glue in place formers R9 and R10. Please note that bores for R9 elevator control are located in upper half of formers. Secure with tape wrapped around fuselage. 27 R10 Insert and glue R7/R8 into nose section, pulling together front of fuselage sides. Glue in place motor mount R20 and secure with clamps and tape.
28 Cut snake outer R21 to a length of 485 mm and glue into formers with 5 minute epoxy, so that it protrudes 30 mm from former R3 and 45 mm from former R11. R11 R21 R3 29 Carefully sand top and bottom contact surfaces of fuselage, then glue in place fuselage sheeting. Upper and lower nose section sheeting consists of three pieces each (R22 to R24 and R25 to R27) of 3 mm balsa. Upper rear fuselage sheeting R 28 is one-piece, lower sheeting consists of parts R29 and tail skid retainer R50.
30 Cut off sheeting material and triangular stock and sand flush with motor mount. Glue in place motor mount cover R30 (1.5 mm birch ply). Make sure bores in R19 match bores in motor mount perfectly. When glue has dried, sand fuselage to shape and round off edges. R30 31 With a razor saw cut out canopy and remove from fuselage. Sand contact surfaces until canopy rests on fuselage without binding.
32 Fit wing into wing saddle and align with centre of fuselage. Through bore in former R2 mark position of wing dowel, then drill with 4 mm. Insert wing dowel F32 in wing and slide wing in place on fuselage. Make sure wing and dowel fit perfectly and without binding. Correct, if necessary, then glue dowel in place. F32 33 Position wing on fuselage and align with centre line. 12 mm from the rear of the wing drill with 4 mm through centre of wing and into R18/R19.
34 Fit canopy former R32 in place in fuselage. To achieve best R32 R33 R34 results, bevel off contact surfaces with upper sheeting, triangular stock and canopy frame. From behind glue magnet R33 and retainer R34 to former (epoxy), then glue former R32 in place and secure with clamps. 35 Fit canopy former R35 in place in rear end of canopy. To achieve best results bevel off contact surfaces with upper sheeting and triangular stock.
36 With drill and file make an opening in rear end of fuselage so that clevis for elevator control can move freely and without binding (ca. 6 mm wide, 7 mm high). If necessary, correct opening when elevator control is installed. 37 Insert 0.8 mm piano wire R38 in snake R39. Rough up snake at one end, epoxy or crimp clevis extender R40 to snake and screw on clevis R41. From the rear slide snake into snake outer. Make sure that clevis moves freely and without binding between fuselage sides.
38 Place tailplane R42 on building board (put cling film under- R45 neath), secure with pins and glue tips R43 in place. Chamfer front edge of elevator R44 for sufficient controll throw. From above glue in place control horn R45 in elevator and sand front of control horn flush with front edge of elevator. R43 R44 R42 R43 39 Glue together fin from parts R46, R47 and R48. R47 Finally, round off front edges of tail assembly with sanding block.
40 Completing the model Mark contact surfaces of fin and tailplane and do not cover. Then cover components of model with your favourite covering material. Iron-on film is the quickest method to achieve an attractive finish. Because of ist texture we suggest you use for your Pepper iron-on fabric, which is available in many attractive colours. As an alternative you may want to cover your model with paper and apply a semi-gloss finish.
Parts List P q0 R1 A R1 B R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 - R24 R25 - R27 R28 R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 Description right fuselage side left fuselage side former former servo tray former battery tray cabin floor former former former former wing saddle reinforcement tailplane slot reinforcement tailplane slot triangular stock triangular stock cabopy frame wing retainer doubler for wing retainer motor mount snake outer top fuselage sheeting
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