® TM WE GET PEOPLE FLYING F4U Corsair .60 ARF ASSEMBLY MANUAL Specifications Wingspan:............... Wing Area: ............. Length: .................... Weight:.................... 65.25 in (1657mm) 752 sq in (48.5 sq dm) 51.5 in (1308mm) 7.5–.8.5 lb (3.4 kg–3.85 kg) Recommended Engines: .61–.75 2-stroke .91–1.0 4-stroke Radio: ......................
Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Covering Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Required Radio and Engines . . . . . .
Contents of Kit A B B C G C 1 B F D E H G F 4 5 3 2 4 Large Parts A. Fuselage B. Wing Set w/Joiner and Ailerons C. Tail Set D. Canopy E. Painted Cowl F. Cockpit w/Radiator G. Wheel Wells H. Dummy Engine HAN2577 HAN2576 HAN2578 HAN2586 HAN2579 HAN2585 HAN2589 HAN2587 Small Parts 1. Fuel Tank Assembly 2. Engine Mount 3. Wheels 4. Tail Wheel Assembly 5.
Other Items Needed (not included in the kit) • Propeller 14x8 - Saito, 12x6 or 13x6 - Evolution • Safety spinner for engine HIGSPN008 - Saito, HIGSPN014 - Evolution • 537 Standard Servo (JRPS537) (5) or equivalent • 703 Low–Profile Retract Servo (JRPS703) • Large servo Arm w/Screw (JRPA212) • 9" Servo Lead Extension (JRPA097) (2) • 12" Servo Lead Extension (JRPA098) (2) Additional Required Tools and Adhesives Tools • Adjustable wrench • Canopy Scissors (DYN2517) • Drill • Drill Bit: 1/16”, 5/64", 3/32”, 9
Before Starting Assembly Before beginning the assembly of the Corsair, remove each part from its bag for inspection. Closely inspect the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact the place of purchase. If you find any wrinkles in the covering, use a heat gun or covering iron to remove them. Use caution while working around areas where the colors overlap to prevent separating the colors.
Section 1: Joining the Wing Halves Required Parts • Left and right wing panels • Center wing panel • Wing joiner (2) • Wing dowels (2) Required Tools and Adhesives • Masking tape • 30-minute epoxy • Epoxy brush • Mixing stick • Rubbing alcohol • Paper towels Step 2 Remove the tape from the string located in the outer wing panel. Tape the string to the retract linkage so it can be accessed later. Step 1 Pull the retract linkage to extend the retract.
Section 1: Joining the Wing Halves Step 4 Test the fit of the wing joiner into one of the outer wing panels. The joiner should slide into the panel with little resistance up to the line drawn on the joiner. Lightly sand the joiner as necessary to achieve a proper fit. Note: The joiner will be angled towards the bottom of the wing. Step 5 Test the fit of the wing joiner into the outer wing panel. The joiner should slide into the panel with little resistance up to the line drawn on the joiner.
Section 1: Joining the Wing Halves Hint: It is extremely important to use plenty of epoxy when joining the wing panels. It will also be helpful to use wax paper under the wing joint to avoid gluing the wing to your work surface. Step 8 Mix approximately 1 ounce of 30-minute epoxy. Using an epoxy brush, apply a generous amount of epoxy to the wing joiner cavity of the outer wing panel. Step 9 Completely coat the short half of the wing joiner with epoxy.
Section 1: Joining the Wing Halves Step 11 Apply epoxy to the exposed portion of the wing joiner. Step 12 Apply epoxy to root wing rib of both panels. Step 14 Use masking tape to securely hold the wing panels together. Allow the epoxy to fully cure before continuing to the next section. Step 15 Repeat Steps 1 through 14 for the remaining wing panel. Step 16 Locate the two 1/4" x 11/4" wing dowels. Use 30minute epoxy to glue the wing dowels into the center panel.
Section 2: Attaching the Wing Required Parts • Assembled wing • Fuselage • 1/4-20 blind nut (2) • 1/4" washer (2) 1 • 1/4-20 x 1 /2" socket head bolt (2) Step 3 Use the two 1/4 x 11/2" socket head bolts and 1/4" washers to attach the wing to the fuselage. Required Tools and Adhesives • 30-minute epoxy • Pliers • Hex Wrench: 3/16" Step 1 Locate the two 1/4-20 blind nuts. Mix a small amount of 30-minute epoxy and apply it to the barbs of the blind nut.
Section 3: Installing the Horizontal Stabilizer Required Parts • Assembled wing • Stabilizer • Fuselage • Elevator joiner wire Required Tools and Adhesives • Hobby knife • Felt-tipped pen • Ruler • 30-minute epoxy Step 1 Slide the stab into the fuselage, making sure the stabilizer is as far forward as possible. Center the stab in the opening by measuring the distance from the fuselage to each tip. The stab is aligned when both measurements are identical.
Section 3: Installing the Horizontal Stabilizer Step 4 After verifying the alignment of the stabilizer, use a felt-tipped pen to trace the outline of the fuselage on the stab. Step 6 Slide the elevator joiner wire into the slot for the stabilizer. Slide the stabilizer partially back into the slot. Step 5 Remove the stab and use a hobby knife with a new blade to remove the covering 1/16" inside the lines just drawn. Use rubbing alcohol and a paper towel to remove the lines once they are no longer needed.
Section 4: Installing the Vertical Stabilizer Required Parts • Fuselage assembly • Fin • Tail wheel wire • Steering control arm • Tail wheel wire support bracket Step 2 Locate the tail wheel wire. Slide the steering control arm onto the wire as shown. Required Tools and Adhesives • 30-minute epoxy • 6-minute epoxy • Square • Hobby knife • Pliers • Ruler Step 1 Remove the covering from the top of the fuselage for the vertical fin and from the bottom of the fuselage for the tail wheel wire.
Section 4: Installing the Vertical Stabilizer Step 4 Remove the fin and use a hobby knife with a new blade to remove the covering 1/16" below the lines just drawn. Use rubbing alcohol and a paper towel to remove the lines once they are no longer needed. Note: Use care not to cut into the underlying wood and weaken the structure. Doing so could cause the fin to fail in flight, resulting in the loss of your airplane.
Section 4: Installing the Vertical Stabilizer Step 8 Mix 1/2 ounce of 30-minute epoxy. Apply the epoxy to both the exposed wood on the fin and the slot in the fuselage. Use care not to get epoxy in the tail wheel wire support bracket. Insert the fin and use tape to hold the fin in position until the epoxy fully cures. Step 10 Measure 3/4" up from the fuselage and mark the tail wheel wire. Position the wire so the tail wheel will be parallel to the runway.
Section 5: Installing the Ailerons Required Parts • Wing • Aileron (left and right) • CA hinges (6) Required Tools and Adhesives • Thin CA • T-Pins Step 1 Locate three CA hinges. Place a T-pin in the center of each hinge. Note: Do not use CA accelerator during the hinging process. The CA must be allowed to soak into the hinge to provide the best bond. Using accelerator will not provide enough time for this process. Step 2 Place the hinges in the precut slots in the aileron.
Section 5: Installing the Ailerons Step 5 Firmly grasp the wing and aileron and gently pull on the aileron to ensure the hinges are secure and cannot be pulled apart. Use caution when gripping the wing and aileron to avoid crushing the structure. Work the aileron up and down several times to work in the hinges and check for proper movement. Step 7 Repeat Steps 1 through 6 for the remaining aileron.
Section 5: Installing the Ailerons Step 2 Locate three CA hinges. Place a T-pin in the center of the hinges. Place the hinges into the elevator half. Note: You can combine the previous step with the following step if you like. This will hold the elevator in position while the epoxy cures. Step 5 Check to make sure the elevator moves freely. It should not rub against the stabilizer at the tip. Check to make sure the hinge gap between the elevator and stabilizer is roughly 1/64".
Section 5: Installing the Ailerons Step 7 Hold the remaining elevator in position against the stabilizer. Mark the location of the elevator joiner wire onto the elevator. Step 8 Drill the location marked in the previous step using a 9/64" drill bit. Step 9 Repeat Steps 2 through 6 to install the remaining elevator half. Section 7: Installing the Rudder Required Parts • Fuselage assembly • CA hinge (3) • Rudder Step 1 Hold the rudder in position against the fin.
Section 7: Installing the Rudder Step 2 Drill the location marked in the previous step using a 1/8" drill bit. Step 5 Locate two CA hinges and place a T-pin in the center of each hinge. Place the hinges into the rudder. Step 6 Test fit the rudder to the fin and tail wheel wire. The gap between the rudder and fin should be a maximum of approximately 1/64". Step 3 Use a hobby knife to cut a groove for the tail wheel wire into the leading edge of the fin from the hole to the bottom of the rudder.
Section 7: Installing the Rudder Step 10 Once the CA and epoxy have fully cured, gently pull on the fin and rudder to make sure the hinges are well glued. Flex the rudder a few times to break in the hinges. Step 11 Align the rudder with the fin. Position the rudder lower trim piece onto the fuselage directly below the rudder. Trace the outline of the trim piece onto the fuselage. Step 12 Remove the covering from the fuselage and the bottom of the trim piece.
Section 8: Retract Linkage Installation Required Parts • Quick connector (2) • 3mm set screw (2) 1 • 3 /4" main wheel (2) • 5/32" wheel collar (2) • Retract servo tray • 3mm set screw (2) • Retract servo tray mount (2) • Quick connector washer (2) • Quick connector retainer (2) Step 3 Locate the retract servo tray. Use 6-minute epoxy to glue the servo tray into position.
Section 8: Retract Linkage Installation Step 6 Use a 5/64" drill bit to drill the appropriate holes in the arm. Step 9 With the retract servo in the retracted position, push the retract linkage to manually retract the landing gear. Install 3mm set screws into the quick connectors and tighten them to secure the retract linkage. Step 7 Attach two quick connectors to the servo arm using quick connector washers and retainers. Step 10 It is important to check the actuation of the retracts.
Section 8: Retract Linkage Installation Hint: Adjustments and fine tuning can also be made to the retract linkages from inside the wheel wells. Step 11 Install the wheel wells after adjusting the retracts. Roughen the bottom side of the well and surrounding covering using medium sandpaper. Glue the wells using 6-minute epoxy. Step 12 Install a wheel and two wheel collars on the main landing gear. The order of items is 5/32" wheel collar, wheel, and then another wheel collar.
Section 9: Engine Installation Required Parts • Fuselage • Engine mount (2) • 8-32 nylon lock nut (4) • 8-32 blind nut (4) • #8 washer (8) • Engine 1 • 8-32 x 1 /4" socket head screw (4) • 8-32 x 1" socket head screw (4) Required Tools and Adhesives • Hex Wrench: 9/64" • Ruler • Adjustable wrench • 11/32" socket wrench Step 1 Locate the engine mount and the associated hardware.
Section 9: Engine Installation Step 5 Center the engine mount in relationship to the oval holes in the firewall. Tighten the bolts holding the mount to the firewall. (Remember to make sure the barbs on the blind nuts go into the backside of the firewall.
Section 10: Throttle Pushrod Installation Step 2 Drill a 5/32” hole in former 2 that corresponds to the location of the hole drilled in the firewall. Step 3 Test fit the throttle pushrod tube through the firewall, through former 2, and into the fuselage. Once satisfied with the fit, roughen the tube using medium sandpaper. Slide the tube back into position and use medium CA to glue it to the firewall.
Section 10: Throttle Pushrod Installation Step 6 Attach the "Z" bend on the throttle pushrod wire onto the carburetor arm. Slide the pushrod wire into the tube and secure the engine to the firewall.
Section 11: Fuel Tank Assembly Step 2 Locate the rubber stopper. Insert the shorter metal fuel tube into one of the holes in the stopper so that an equal amount of tube extends from each side of the stopper. This tube will be the fuel tank pickup that provides fuel to the engine. Step 3 Slide the smaller cap over the tube on the smaller end of the rubber stopper. This end will be inserted into the fuel tank. The larger cap is placed on the side of the rubber stopper that makes the cap.
Section 11: Fuel Tank Assembly Step 6 Locate the short piece of silicone fuel tubing and the fuel tank clunk. Install the clunk onto one end of the silicone tubing. Slide the silicone tubing (end opposite the clunk) onto the fuel tank pickup tube (straight tube) in the stopper. Step 7 Carefully insert the stopper assembly into the fuel tank. Note the position of the vent tube; it must be up at the top portion of the fuel tank to function properly.
Section 12: Fuel Tank Installation Required Parts • Fuselage assembly • Fuel tubing • Fuel tank assembly Required Tools and Adhesives • Foam: 1/4" • Masking tape Step 3 Install the fuel tank into the fuselage. Make any necessary supports to keep the tank from moving during flight. When installing the fuel tank, make sure to have a piece of foam at any point that contacts any structure inside the fuselage.
Section 12: Fuel Tank Installation Step 5 Make the proper connections to the engine, using the engine manufacturer’s instructions. If you are using a four-stoke, make sure to route the crankcase vent to the outside of the cowling.
Section 13: Radio Installation Step 3 Remove the servo and drill the holes for the servo mounting screws using a 1/16" drill bit. Hint: Place a drop of thin CA onto each screw hole to harden the wood around the hole. Allow the CA to fully cure before installing the servos. Step 4 Secure the throttle servo using the screws provided with the servo. Step 5 Remove the covering from the opening on the bottom of the fuselage for the rudder servo. Step 6 Connect a 9" Servo Extension (JRPA097) to the servo lead.
Section 13: Radio Installation Step 7 Temporarily install the rudder servo. Mark the locations for the servo screws using a felt-tipped pen. Remove the servo and drill the holes for the servo mounting screws using a 1/16" drill bit. Secure the rudder servo using the screws provided with the servo. Step 9 Mount the radio switch to the side of the fuselage. Step 10 Wrap the receiver and receiver battery in protective foam to prevent damage that may be caused by engine vibration.
Section 13: Radio Installation Step 12 Temporarily mount the receiver and battery into the fuselage. It may be necessary to relocate the battery forward or aft to balance the model as described in the section "Control Throws and Center of Gravity." Step 13 Route the antenna through the bottom of the fuselage and secure it to a location at the tail with rubber bands. Step 14 Remove the aileron hatch from the wing. Remove the covering from the slot for the aileron horn.
Section 13: Radio Installation Step 17 Place the aileron servo between the mounting blocks and use a felt-tipped pen to mark the location of the four servo mounting screws. Note that the servo must not touch the hatch in order to isolate engine vibration. Note: Before mounting the servo, it is suggested to electronically center the servo using the transmitter, then install the servo arm to avoid having to remove the servo and center the arm later.
Section 13: Radio Installation Step 22 Remove the servo hatch cover and re-drill the holes using a 5/64" drill bit. Use 2–3 drops of thin CA to harden the underlying wood. This will prevent the screws from crushing the wood when they are tightened. Secure the hatch using four #2 x 3/8” screws. Step 21 Place the hatch cover in position in the aileron opening. Measure in 1/8" on all four sides of the hatch. Drill four 1/16" holes at the intersections of the lines as shown.
Section 14: Linkage Installation Required Parts • Fuselage assembly • 6" pushrod wire (3) • Nylon clevis (4) • Nylon control horn (3) • Quick connector • Quick connector backplate • Wing assembly • 7" pushrod wire • Nylon wire keeper (4) • 2-56 x 3/4" screw (6) • M3x6 machine screw Step 3 Position the control horn on the elevator so the horn aligns with the hinge line of the elevator. Mark the position for the mounting holes using a felt-tipped pen.
Section 14: Linkage Installation Step 5 Place 2–3 drops of thin CA into the hole to harden the wood. Repeat this for each of the three holes. Step 7 Center the elevator servo electronically using the radio system. Install a servo arm onto the elevator servo. Attach the pushrod with clevis to the control horn. Physically place the elevator control surface in neutral. Mark the pushrod where it crosses the holes in the servo arm.
Section 14: Linkage Installation Step 9 Cut the wire 3/8" above the bend. Step 12 Center the rudder servo electronically using the radio system. Install a servo arm onto the rudder servo. Attach the pushrod with clevis to the steering control horn. Physically place the steering control horn parallel to the rudder servo arm. Mark the pushrod where it crosses the holes in the servo arm. Step 10 Slide the wire through the outer hole in the elevator servo arm. Secure the wire using a nylon wire keeper.
Section 14: Linkage Installation Step 14 Slide the wire through the outer hole in the rudder servo arm. Secure the wire using a nylon wire keeper. It may be necessary to drill out the hole in the servo arm using a 5/64" drill bit. Note: Use a 1/4" piece of fuel tubing on the clevis to keep it from opening during flight. Step 15 Position the rudder in neutral. Secure the steering control horn to the tail gear wire using a 3mm set screw.
Section 14: Linkage Installation Step 20 Slide a clevis retainer onto a nylon clevis. Thread a clevis onto a 6" wire a minimum of 10 turns. Step 24 Repeat Steps 16 through 23 for the other aileron servo. Step 21 Center the aileron servo electronically using the radio system. Install a servo arm onto the aileron servo. Attach the pushrod with clevis to the control horn. Physically place the aileron control surface in neutral. Mark the pushrod where it crosses the holes in the servo arm.
Section 14: Linkage Installation Step 27 Center the throttle stick and trim with both the receiver and transmitter on. Install the throttle servo arm in the neutral position. Step 28 Move the servo to the throttle closed position using the radio system. Manually move the throttle arm on the carburetor to the closed position. Use a 3mm set screw to secure the throttle pushrod wire. Step 30 Use scrap wood to make a brace for the throttle pushrod tube near the servo as shown.
Section 15: Cowling Installation Required Parts • Fuselage assembly • Cowling • #2 x 1/2" sheet metal screw (4) • 5/8" x 3/4" x 3/4" cowl mounting block (4) • Dummy radial engine Step 2 Use 6-minute epoxy to glue the dummy radial inside the cowl. Required Tools and Adhesives • Drill • Drill Bit: 1/16", 1/8" • Hobby scissors • 6-minute epoxy • Phillips screwdriver (small) • Rotary tool with sanding drum Step 1 Locate the dummy radial engine.
Section 15: Cowling Installation Step 4 Sand four areas onto the firewall that are 45 degrees from the centerlines. The areas must be large enough to fit the cowl mounting blocks. Step 5 Position the cowl mounting blocks so the rounded edge of the block extends 1/4" from the outside edge of the fuselage. Glue the cowl mounting blocks to the firewall using 6-minute epoxy. Step 6 Use a piece of cardstock to indicate the location of the engine head, needle valve and cowl mounting blocks.
Section 15: Cowling Installation Step 8 Remove the cowl and remove the necessary material to fit the cowl over the engine. Install the engine back onto the firewall and test fit the cowl over the engine. Use a small amount of threadlock on the four bolts to prevent them from loosening during flight. Step 10 Use the cardstock from Step 1 to locate the positions for the cowling screws. The goal is to drill into the cowl mounting blocks for the four screws that hold the cowling.
Section 16: Canopy and Decal Installation Required Parts • Fuselage assembly • Canopy • #2 x 1/2" sheet metal screw (2) Required Tools and Adhesives • Canopy glue (RC-56) • Zap-A-Dap-A-Goo • Sandpaper (medium grit) Step 2 Position the canopy onto the fuselage. Trace around the canopy and onto the fuselage using a felt-tipped pen. Step 1 Install a pilot of your choosing. Use epoxy or Zap-A-Dap-A-Goo to secure the pilot. Step 2 Use Lexan ® scissors to trim the backrest.
Section 16: Canopy and Decal Installation Step 4 Apply a bead of RCZ56 Canopy Glue (ZINJ5007) around the inside edge of the canopy. Position the canopy onto the hatch. Use tape to hold the canopy secure until the glue fully cures. Step 6 Use Lexan ® scissors to trim the radiators. Use Zap-A-Dap-A-Goo to glue the radiators into position on the wing. Step 5 Apply the decals. Use the photos on the box to aid in their location.
Control Throws and Center of Gravity Recommended CG Location An important part of preparing the aircraft for flight is properly balancing the model. This is especially important when various engines are mounted. Caution: Do not inadvertently skip this step! The recommended Center of Gravity (CG) location for the Corsair is 5" behind the leading edge of the wing against the fuselage. Make sure the gear is retracted when checking the CG, as the CG will change depending on the gear position.
2003 Official AMA National Model Aircraft Safety Code Effective January 1, 2003 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. 2) I will not fly my model higher than approximately 400 feet within 3 miles of an airport without notifying the airport operator.
2003 Official AMA National Model Aircraft Safety Code Continued 4) I will operate my model using only radio control frequencies currently allowed by the Federal Communications Commission. (Only properly licensed Amateurs are authorized to operate equipment on Amateur Band frequencies.) 5) Flying sites separated by three miles or more are considered safe from site-to site interference, even when both sites use the same frequencies.
® TM WE GET PEOPLE FLYING © 2003, Horizon Hobby, Inc. 4105 Fieldstone Road Champaign, Illinois 61822 (877) 504-0233 www.horizonhobby.
