ASSEMBLY MANUAL Specifications Wingspan: . . . . . . 63 in (1600 mm) Length: . . . . . . . 52.5 in (1334 mm) Wing Area: . 710 sq in (45.8 sq dm) Weight: . . . . . 5–6 lb (2.27–2.
Table of Contents Introduction ............................................................................ 2 Warning ............................................................................ 2 Contents of Kit.......................................................................... 3 Additional Required Equipment ................................................ 3 Additional Required Adhesives and Tools ................................ 4 Required Field Equipment ..........................................
Contents of Kit Large Parts a. Fuselage (HAN2452) b. Wing Set with Joiner (HAN2451) c. Tail Set (HAN2453) d. Pushrods e. Landing Gear Set (HAN2454) a d c b e 2 7 4 6 1 5 3 Small Parts 1. Fuel Tank (HAN2479) 2. Engine Mount and Hardware 3. Wheel Collars 4. Clevises and Wire Keepers 5. Control Horns and Hardware 6. CA Hinges 7. Aileron Servo Mount 8. Decal Set (HAN2455) (not pictured) Additional Required Equipment • 4-channel radio (minimum) • 4 standard servos (JRP5527) • Engine .40–.48 2-cycle .
Additional Required Adhesives and Tools Adhesives • CA (cyanoacrylate) Glue: thick and thin • CA remover/debonder • 6-minute epoxy • 30-minute epoxy • Threadlock (Pacer Z42) Tools • Hobby knife w/#11 blade • Drill • Drill Bits: 1/16” • Phillips screwdriver • Pliers Other • Measuring device (e.g.
Section 1: Hinging the Ailerons Parts Needed • Right wing panel w/aileron • Left wing panel w/aileron • CA hinges (8) Step 3 Trial fit the aileron to the wing; make sure there is no more than 1/32" gap along the hinge line. Once satisfied with the fit, remove the aileron. Tools and Adhesives Needed • Thin CA • CA remover/debonder • 6-minute epoxy • Masking tape • T-pins • Rubbing alcohol • Paper towels Note: The photos and instructions in this section are for the right wing panel.
Section 1: Hinging the Ailerons Continued Note: The hinges supplied with your Alpha™ Trainer ARF are constructed of a special material that allows the thin CA to “wick” or penetrate and distribute throughout the hinge, securely bonding them to the wood structure. It is important that you properly secure the hinges in place per these instructions using high-quality thin CA glue. Step 6 Hinge the opposite wing panel and aileron by repeating Steps 2–5.
Section 2: Joining the Wing Halves Parts Needed • Right and left wing halves • Wing joiner Tools and Adhesives Needed • 30-minute epoxy • Ruler • Felt-tipped pen or pencil • Rubbing alcohol • Paper towels • Wax paper Step 3 Use masking tape to hold the wing halves together while you check for the correct dihedral angle. Place the wing on a large flat surface, with one wing panel resting flat on the surface the tip of the opposite wing panel should be 5" from the flat surface.
Section 2: Joining the Wing Halves Continued Step 6 Apply a generous amount of epoxy to the other wing panel joiner cavity. Step 7 Apply epoxy to the exposed portion of the wing joiner and to both wing roots and carefully slide both wing panels together. Firmly press both halves together allowing the epoxy to run out. Using alcohol and paper towels, wipe off the excess epoxy. Check to make sure there are no visible gaps between the two wing panels.
Section 3: Installing the Aileron Servo Tray Parts Needed • Completed wing • Plywood servo tray • Wood servo rails • Aileron servo w/mounting hardware Tools and Adhesives Needed • 6-minute epoxy • Thick CA • Hobby knife Step 2 Install the mounting hardware (rubber grommets and brass eyelets) supplied with your radio system on to the aileron servo. Temporarily install the aileron servo on the servo tray as shown and test fit the entire assembly to the wing.
Section 3: Installing the Aileron Servo Tray Continued Step 3 Use a felt-tipped pen or pencil to trace the outline of servo tray onto the bottom of the wing. Remove the servo and servo tray. Using a sharp hobby knife, cut away the covering along the line you just traced. Caution: Only cut deep enough to cut the covering. Do not cut into the wood sheeting underneath. 10 Step 4 Mix a small amount of 6-minute epoxy (approximately 1/4 ounce) and coat both the bare wood of the wing and the servo tray rails.
Section 4: Installing the Aileron Servo and Linkages Parts Needed • Wing assembly • Aileron servo • Aileron mounting screws (4) • Aileron control wire (2) • Nylon clevis w/keeper (2) • Wire keeper (2) • Nylon horn bracket (2) Tools and Adhesives Needed • Thin CA • Drill • Drill Bit: 1/16" • Small Phillips screwdriver • Pliers • Felt-tipped pen • Ruler Step 1 Temporarily install the aileron servo into the wing oriented as shown. Using a felt-tipped pen, mark the location of the servo mounting screws.
Section 4: Installing the Aileron Servo and Linkages Continued Step 6 Install an “X” servo arm onto the aileron servo as shown. You should clip off the shorter arms so they will not interfere with the control wires. Position the servo arm so it is parallel with the trailing edge of the wing. Step 7 Use masking tape to hold the ailerons in their neutral position, (even with the wings trailing edge).
Section 5: Installing the Landing Gear and Wheels Parts Needed • Main landing gear wire (2) • Nose landing gear wire • 2 3/4" main wheel (2) • 2 1/2" nose wheel • Large wheel collar w/setscrew (6) • Nylon nose wheel steering block w/arm • Nylon landing gear strap w/1/2" wood screws Step 3 Locate the mounting screw holes drilled on either side of the landing gear wires. Secure the main landing gear wires using the straps and the 1/2" wood screws provided with your model.
Section 5: Installing the Landing Gear and Wheels Continued Step 5 Locate the nose wheel steering block. Mount the steering block to the firewall of the fuselage as shown. Step 6 Slide the nose gear wire through the steering block and steering arm as shown and tighten the setscrew on the steering arm to secure the nose gear. You want the setscrew to tighten against the flat ground into the nose gear wire.
Section 6: Installing the Horizontal and Vertical Stabilizer Parts Needed • Fuselage assembly • Wing assembly • Horizontal stabilizer • Vertical stabilizer Step 2 Mark the center of the stabilizer saddle at the trailing edge of the saddle as shown. Tools and Adhesives Needed • 30-minute epoxy • Hobby knife • 90-degree square • Tape measure • Masking tape • Rubbing alcohol • Paper towels Step 1 Locate the horizontal stabilizer and elevator assembly and remove the elevator.
Section 6: Installing the Horizontal and Vertical Stabilizer Continued 16 Step 4 With the horizontal stabilizer properly aligned, use a felt-tipped pen or pencil to carefully mark the bottom of the stabilizer where it meets the fuselage. Step 7 Mix at least 1/ 2 ounce of 30-minute epoxy and coat the horizontal stabilizer saddle and stabilizer center section. Step 5 Remove the stabilizer.
Section 6: Installing the Horizontal and Vertical Stabilizer Continued Step 10 Locate the vertical fin and rudder assembly. Remove the rudder and test fit the vertical fin in place. Make sure the rear of the fin sits flat on the forward portion of the stabilizer. Once satisfied, use a felt-tipped pen to mark the fin where it inserts into the fuselage. Also mark the top of the stabilizer where the fin contacts.
Section 7: Hinging the Elevator and Rudder Parts Needed • Fuselage assembly • Elevator • Rudder • Hinges (7) Step 3 Using high-quality thin CA glue, deflect the elevator down and completely saturate each hinge.
Section 7: Hinging the Elevator and Rudder Continued Step 6 Install the three rudder hinges as you did for the elevator placing a T-pin through the center of each hinge to keep it centered while installing the rudder. Install the rudder and remove the T-pins and push the rudder against fin until there is only a slight gap (1/32" or less). Deflect the rudder in one direction and using high quality thin CA glue completely saturate each hinge.
Section 8: Installing the Elevator and Rudder Control Horns Parts Needed • Fuselage assembly • Control horn w/back plate (2) • Mounting screws (6) Step 3 Drill 1/16" holes through the elevator as marked. Make sure to drill these holes parallel to each other to allow the back plate of the horn to fit properly.
Section 8: Installing the Elevator and Rudder Control Horns Continued Step 5 Measure 3/4" up from the bottom of the rudder on the left side. Mark the location with a felt-tipped pen or pencil. This mark will serve as the center for the rudder control horn. Step 7 Using a 1/16" drill bit, drill the mounting screw holes on the marks made in the previous step and install the rudder control horn, using the three screws and back plate provided.
Section 9: Assembling the Fuel Tank Parts Needed • Metal tubes (2) • Clunk (fuel pickup) • Fuel pickup tubing • Fuel tank • Metal caps (2) • Rubber stopper • 3mm screw Step 3 Slide the smaller of the two caps over the tube on the smaller end of the rubber stopper. The small end will be inserted into the fuel tank. The larger cap is placed on the other side of the rubber stopper that makes the cap. Tools and Adhesives Needed • Hobby knife • Medium screwdriver Step 1 Locate the tank parts.
Section 9: Assembling the Fuel Tank Continued Step 6 Carefully insert the assembly into the fuel tank. Note the position of the vent tube. It must be at the top portion of the fuel tank to function properly. Also, it may be necessary to shorten the length of the fuel pickup tubing to ensure the clunk does not rub against the back of the fuel tank. You should be able to turn the tank upside down, which allows the clunk to freely drop to the top of the tank.
Section 10: Mounting the Engine Parts Needed • Fuselage assembly • Engine mount w/hardware • Propeller • Spinner Tools and Adhesives Needed • Phillips screwdriver • Threadlock (Step 3 Photo) Step 1 Locate the supplied engine mount and mounting hardware [8-32 x 3/4" screw (4), 8-32 x 1" screw (4), 8-32 locknuts (4), #8 washers (4)]. (Step 3 Photo) Step 4 Install the muffler onto your engine, using the hardware supplied with your engine.
Section 11: Installing the Radio Parts Needed • Fuselage assembly • Receiver • Receiver battery • Standard servos (3) • RC foam • 12" servo lead Step 3 Mount the battery switch to the left side of the fuselage as shown. Tools and Adhesives Needed • Phillips screwdriver • Hobby knife w/#11 blade • Drill • Drill Bit: 1/16" Step 1 Install the mounting hardware (rubber grommets and brass eyelets) supplied with your radio system on to the elevator, rudder and throttle servos.
Section 11: Installing the Radio Continued Step 6 Place the third layer over the receiver and battery pack, leaving the aileron servo lead free. Locate the plywood radio compartment cover and slide it into the fuselage until it contacts the back of the fuel tank. Step 7 Drill a 1/16" pilot hole through the cover and into the post in the fuselage. Secure the cover with the screw provided in the Alpha ARF kit.
Section 12: Installing the Rudder, Elevator and Throttle Linkage Parts Needed • Fuselage assembly • Nylon clevis w/clevis keepers (3) • L-bend keepers (3) • Easy connector • Control wires (4) - 28 3/4" threaded on one end ............ Elevator - 25 1/2" threaded on one end ............ Rudder - 20" threaded on one end ................ Throttle - 17 3/4" no threads ............................
Section 12: Installing the Rudder, Elevator and Throttle Linkage Continued Step 4 Remove the control wire and make a 90-degree “L” bend as shown. Cut off the excess wire 5/16" from the bend. Remove the clevis and slide the control wire through the tube from inside the fuselage and connect the wire to the servo arm using an L-bend keeper. Thread the clevis back on to the wire and reconnect the clevis to the control horn on the elevator.
Section 12: Installing the Rudder, Elevator and Throttle Linkage Continued Step 8 Locate the nose wheel steering control wire (17 3/4" non-threaded) and make a Z-bend on one end. Slide the wire through the pre-installed steering tube in the firewall and through the easy connector on the rudder servo. Remove the steering arm from the nose gear and connect the Z-bend. Re-install the steering arm on to the nose gear.
Section 13: Installing the Spinner and Propeller Parts Needed • Fuselage assembly • Spinner (included) • Evolution 3-bladed trainer propeller (EVOE100P) Tools and Adhesives Needed • Adjustable wrench • Phillips screwdriver Step 3 With the flywheel in place, install the spinner back plate onto the engine as shown. Note: The flywheel is keyed in place onto the engines crankshaft and should be tight against the front engine bearing.
Section 13: Installing the Spinner and Propeller Continued Step 6 Using an adjustable wrench, tighten the prop nut while holding the propeller in place. Step 7 Using a Phillips head screwdriver, secure the spinner cone in place with the three self-tapping screws provided. Warning: The propeller must be securely tightened before attempting to run your evolution engine. Be sure to check the security of the propeller before each flying session.
Section 14: Balancing and Control Throw Recommendations Parts Needed • Fuselage assembly • Wing assembly • Wing dowels (2) • #64 rubber bands (10) (included) Step 1 Install the two wing dowels through the holes located at the front and rear of the wing saddle. Leave an equal amount extending from the sides of the fuselage. (Step 2 Photo) The following control throws are recommended for your first flights.
Preflight Checks at the Flying Field Important: Be sure your batteries are fully charged, per the instructions included with your radio system. Before each flight, check the screws and nuts that secure the metal plate holding the motor in place on the motor mount. Also check the clevises of each control surface for security and presence of a clevis keeper. Perform a ground range check before each day’s flying. Proceed as follows: 1. Do not extend the transmitter antenna. Turn the transmitter on. 2.
2002 Official AMA National Model Aircraft Safety Code Effective January 1, 2002 Model Flying MUST be in accordance with this Code in order for AMA Liability Protection to apply. General 1) I 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.
2002 Official AMA National Model Aircraft Safety Code Continued 7) An RC racing event, whether or not an AMA Rule Book event, is one in which model aircraft compete in flight over a prescribed course with the objective of finishing the course faster to determine the winner. A. In every organized racing event in which contestants, callers and officials are on the course: 1.
® TM WE GET PEOPLE FLYING © Copyright 2002, Horizon Hobby, Inc. 1-800-535-5551 www.horizonhobby.
