Instruction Manual Item No: AL506 Specifications: Wingspan: 2218mm (87.3 in) Length: 1892mm (74.5 in) Wing Area: 100dm2 (1550 sq in) Flying Weight: 7.3kg (16.1 lbs) Engine(not incl.): 50-60cc Gas Radio(not incl.): 4 ch, 6 servos Construction: Balsa and Plywood Features: Designed for high performance scale aerobatics High-quality balsa and plywood material Light weight and strong construction Foam brace on the back of fuselage Enhanced cowling mounting design Hardware package included High-quality, prepainted, fiberglass cowling and wheel pants Nice color scheme with professional covering Picture may not be the same as actual product. Please refer to actual product. We reserve the rights of updating product information, appearance and parameters without notice.
Table of Contents Appendix Parts and Options 21
Fully assemble the model. With a helper, lift the airplane with your index fingers to find the balance point. The balance point (CG) should lie between the two marks on the wing. If not, try to move some parts such as batteries to different position, or add the necessary weight to the nose or tail to obtain the correct balance. Preflight Introduction Congratulations on the purchase of this model airplane. You will enjoy one of the most thrilling experiences the radio control hobby has to offer. The product is a professionally built, radio control model. It is very important that you operate this model responsibly. Please read this instruction manual thoroughly and follow the directions. As a large model, the airplane is critical of proper battery use, control linkage setups and flying techniques. Please pay particular attention to the following areas. Maintain the proper mechanical advantage on all control surface linkages. Check the radio installation and make sure all the control surfaces are moving correctly (i.e. the correct direction and with the recommended throws). Test run the engine and make sure it transitions smoothly from idle to full throttle and back. Also ensure the engine is tuned according to the manufacturer s instructions, and it will run consistently and constantly at full throttle when adjusted. Check all the control horns, servo horns, and clevises to make sure they are secure and in good condition. Replace any items that would be considered questionable. Failure of any of these components in flight would mean the loss of your airplane. Never attempt to make full throttle dives! Large models perform much more like full-size airplane than small models. If the airframe goes too fast, such as in a high throttle dive, it may fail. The model should be flown like a full-scale airplane. Throttle management is absolutely necessary. Hardware checks Double-check the setscrews in all control horns to be sure they are very tight. Periodically check these to be sure they have not loosened over time. Always use threadlock on metal-to-metal fasteners. Receiver Battery Selection Be sure adequate batteries are used to power the receiver. It is recommended that two identical 6-volt receiver packs are used. Each pack must have a minimum of 2700mAh capacity. Use packs of 3000mAh when super high torque servos are used. Range check Always range check the radio system per the manufacturer's instructions before the initial test flight and periodically afterward. Check the voltage of the on-board packs ALWAYS use an ESV with a 1-amp load to check the receiver battery packs and the ignition pack before each and every flight. If there is any doubt that the packs are questionable, DO NOT FLY until the packs are recharged. Safety Precautions and Warnings This is a sophisticated hobby Product and not a toy. It must be operated with caution and common sense and requires some basic mechanical ability. Failure to operate this Product in a safe and responsible manner could result in injury or damage to the Product or other property. This Product is not intended for use by children without direct adult supervision. The Product manual contains instructions for safety, operation and maintenance. It is essential to read and follow all the instructions and warnings in the manual, prior to assembly, setup or use, in order to operate correctly and avoid damage or injury. This model is controlled by a radio signal that is subject to interference from many sources outside your control. This interference can cause momentary loss of control so it is advisable to always keep a safe distance in all directions around your model, as this margin will help to avoid collisions or injury. Always operate your model in an open area away from cars, traffic, or people. Never operate the model into the street or populated areas for any reason. Never operate your model with low transmitter batteries. Carefully follow the directions and warnings for this and any optional support equipment (radio, engine, chargers, rechargeable battery packs, etc.) that you use. Keep all chemicals, small parts and anything electrical out of the reach of children. Moisture causes damage to electronics. Avoid water exposure to all equipment not specifically designed and protected for this purpose. Limited Warranty & Limits of Liability We guarantee this kit to be free from defects in both material and workmanship at the date of purchase. 20 1
This warranty does not cover cosmetic damage or damage due to acts of God, accident, misuse, abuse, negligence, commercial use, or modification of or to any part of the Product. This warranty does not cover damage due to improper installation, operation, or maintenance. This warranty is limited to the original purchaser and is not transferable. In no case shall our company s liability exceed the original cost of the purchased product and will not cover consequential, incidental or collateral damage. Our company reserves the right to inspect any and all equipment involved in a warranty claim. Repair or replacement decisions are at the sole discretion of our company. Further, our company reserves the right to change or modify this warranty without notice. REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE CONSUMER. As our company has no control over use, setup, final assembly, modification or misuse, no liability shall be assumed nor accepted for any resulting damage or injury. By the act of use, setup or assembly, the user accepts all resulting liability. If you as the purchaser or user are not prepared to accept the liability associated with the use of this product, you are advised to return this product immediately in new and unused condition to the place of purchase. Radio Setup A 7-channel or greater computer radio is highly recommended. This allows the following features: Mixing the right aileron to the left aileron (flaperon mix) Electronically adjustable aileron differential Mixing the right elevator to the left elevator (dual elevator mixing) Independent travel and trim adjustments of each elevator half Mixing the right rudder servo to the left rudder servo (not required when using a single rudder servo) When you use a 7-channel or greater computer radio, each servo is plugged into its own separate channel. Consult your radio manual for specific details on hookup and programming. Control Throws Contents of Kit AL50601 Fuselage for 50cc Sbach 342 AL50602 Fiberglass Painted Cowling for 50cc Sbach 342 AL50603 Canopy for 50cc Sbach 342 AL50604 Rudder for 50cc Sbach 342 AL50605 Left Wing Panel w/ Aileron for 50cc Sbach 342 AL50606 Right Wing Panel w/ Aileron for 50cc Sbach 342 AL50612 Left Stabilizer w/ Elevator for 50cc Sbach 342 AL50613 Right Stabilizer w/ Elevator for 50cc Sbach 342 AL50616 Landing Gear for 50cc Sbach 342 AL50617 Wheel Pants for 50cc Sbach 342 AL50620 Wing Tube for 50cc Sbach 342 AL50621 Stabilizer Tube for 50cc Sbach 342 AL50622 Decal Set for 50cc Sbach 342 The following is our recommended control throws for your reference. Aileron Standard 20 up 20 down 3D 40 up 40 down Elevator Recommended Center of Gravity (CG) Correctly balancing an aerobatic model is critical to its performance and flight characteristics. Checking the balance on this model is best done with two people. Rudder Standard 3D Standard 3D 15 up 40 up 26 left 43 left 15 down 40 down 26 right 43 right Measure back 30%-33% of the whole wing root s length from the leading edge and mark the CG range with a felt-tipped pen at the wing tip. This is the recommended center of gravity (CG) range. 2 19
Step 9 Install the switch for the ignition in the switch hatch on the side of the fuselage as shown. Additional Required Items 0 Secure the battery for the ignition inside the fuselage using a hook and loop strap. Make sure to add a few pieces of foam between the fuselage and battery to prevent damage to the battery caused by vibration. Connect the battery to the ignition switch. 1 Attach the fuel line from the fuel tank to the carburetor. Make sure the line is from the clunk and not the vent line. 2 Route the vent line from the fuel tank out of the bottom of the cowling. Radio Equipment 4-channel radio system (minimum) 1 standard servo for throttle 5 hi-torque servos Recommended Engines D-55, Q-50 Propeller (consult engine instructions) Servo Extensions Y-Harness Adhesives 6-minute epoxy 30-minute epoxy Thick CA glue Threadlock Tools Adjustable wrench (small) Drill (drill press preferred) Hook and loop straps Foam Hex wrench Hobby knife Phillips screwdriver (small) Pliers Scissors Square Measuring device (e.g. ruler, tape measure) 3 Make any necessary cutouts to clear the engine components in the cowling. Remove a section from the bottom of the cowling near the exhaust pipe for cooling outlet as shown. This opening is necessary to allow cooling air to pass through the cowling to prevent overheating of your engine. Servo Selection The servos used for the control surfaces of this model must have a minimum of 9kg-cm (125 oz-in) of servo torque. The servos with metal gear are strongly recommended. 4 Slide and lock the cowling to the fuselage and then secure the cowling using two screws. Mount the propeller and spinner to complete the procedure. Note: As the cowling mounting screw is inside the fuselage under the hatch, you need to open the hatch before accessing the screw. To open the hatch, just remove the screws holding it on both sides of the fuselage and lift the hatch from the fuselage. Before Starting Assembly Before beginning the assembly of the model, 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. 18 3
Section 1 Aileron Servo Installation Wing panel ( left and right ) Locate the opening for the aileron servo at the bottom of the aileron. Carefully remove the covering from the opening using a hobby knife. The vertical and horizontal base lines are pre-marked on the firewall. Measure and mark the same distance from the lines for the four engine standoff screws. The firewall is already mounted correctly to provide right offset for the engine when the engine standoff center is on the intersection of the above lines. Drill the holes in the firewall for mounting the engine. Install four screws from the back side of the firewall. You may apply epoxy glue here. Plug a servo extension onto the servo. Tie the servo leads together by using a secure connector, or using a ribbon to prevent them from coming loose during flight. Tie a weight to a piece of string. A wheel collar works great in this application. Tie the other end of the string to the servo extension. Install engine using four machined aluminum standoffs, screws and lock washers. Step 6 Install throttle servo with servo arm to the provided throttle servo mount. Drill a hole in the firewall for the throttle linkage to pass. Attach the linkage to the servo arm and throttle. Lower the weight into the wing from the aileron servo opening. Let the weight drop out through the wing root for the servo. Use the string to pull the servo lead through the wing. Secure the servo using the hardware provided with the servo. Attach the servo arm to the servo. Make sure the servo arm is parallel with the hinge line when the servo is at the neutral position. Step 6 Repeat Steps 1 through 5 for the remaining wing panel. Step 7 Install the exhaust pipe to the engine. Step 8 Secure the ignition module to the engine box. Make the connections between the ignition box and engine at this time. 4 17
Wrap the receiver battery in foam and use rubber bands or hook and loop straps to secure the battery to the battery tray. Section 2 Aileron Control Horn Installation Assemble the fuel tank correctly. Be sure to use the gas-compatible stopper and fuel tubing. Place foam on the floor of the tank compartment. Secure the tank in place by wrapping rubber bands or hook and loop straps around the tank and tank floor. Later we will run the fuel lines. Wing panel (left and right) Aileron (left and right) Tape the aileron to the wing. Using a square held in alignment with the outer hole in the servo arm and 90 with the trailing edge of the wing, mark the aileron with a pen where the straight edge intersects the aileron hinge bevel. Locate the hidden switch hatch on the side of the fuselage and open the hatch. Mount the receiver switch in the hatch and then close the hatch door. Section 11 Mounting the Engine and Cowling Measure rearward 10mm (3/8 ) from the top of the aileron bevel and make another mark using a pen. The intersection of the line from and this line will be the position for the control horn. Remove the ailerons from the wing. Use rubbing alcohol to remove any tape residue. Engine and accessories This model accepts gas engines ranging from 50 through 60cc. The following steps show the installation of a 55cc gas engine for your reference. The detailed steps may be different when your selected engine is different. Carefully drill through the aileron at the marked position. Be especially careful when penetrating through the top surface of the aileron, as it s easy to split out the wood and rip the covering. Placing a wooden block under the aileron and drilling slowly will prevent these problems. D-55 Installation Collect the necessary items for the installation of your particular engine. Note: A hardwood block (hard point) is located below the sheeting; you will be drilling through this. Make sure to drill the hole perpendicular to the centerline of the aileron. 16 5
From the top of the aileron, plug the control horn screw through the hole and secure it with the provided nut. Step 6 Repeat Steps 1 through 5 for the remaining aileron. Install the following items onto the axle: washer, wheel and then wheel collar. Note: It may be necessary to drill the hole in the wheel to fit onto the axle. Section 3 Hinging and Sealing the Control Surfaces Wing panel ( left and right ) Aileron (left and right) Properly hinging the control surfaces on this model is very important! Poorly installed hinges affect the model s precision and control response and can also be dangerous. Each and every hinge needs to be securely bonded in place in both the flying surface and the control surface. The hinge pivot points need to be exactly parallel to each other and precisely located on the center of the hinge line. The control surfaces of this model are predrilled for the hinges included in hardware package. Sand each end of the hinges using coarse sandpaper. This will improve the bond of the epoxy to the hinge. Mix some 30-minute epoxy. Using a glue syringe or toothpick, place a sufficient amount of the epoxy into one of the hinge pockets in the aileron leading edge. Install one of the hinge points until the hinge pin center is flush with the leading edge of the aileron. Wipe away any excess epoxy with rubbing alcohol. Continue installing hinges in the leading edge of the aileron. The control surfaces (ailerons) will be installed after the epoxy is fully cured. Note: Be sure that the hinge pivot pins are parallel and flush to the aileron leading edge. It s important to frequently mix a fresh batch of 30-minute epoxy in order to achieve good glue joint penetration. If you notice the epoxy becoming thicker, then mix a new batch! The blind nuts on the wheel pant are pre-installed. Slide the wheel pant to the right position on the wheel. Secure the wheel pant to the landing gear with two screws. Note: Always use threadlock on metal-to-metal fasteners to prevent them from vibrating loose. Install the landing gear to the fuselage using four screws and four lock washers. Repeat Steps 1 through 4 for the remaining landing gear. Section 10 Receiver, Battery and Fuel Tank Installation Use foam and rubber bands (or hook and loop straps) to secure the receiver to the battery tray. 6 15
Remove the bracket and drill pilot holes at the previously marked positions. Assemble the tail wheel bracket and use provided screws to secure the bracket in place. A hardwood plate is positioned in the rear of the fuselage, allowing these screws to be firmly tightened. Hint: Remove the screws and wick thin CA into the holes to strengthen the threads. Then, reinstall the screws. Using the provided springs, hook up the tiller arm to the rudder with the tail wheel. When the epoxy is cured, work each hinge throughout its full motion several times using your hands. This will break free any epoxy that may have found its way into the hinge joint. Move the hinge throughout its full travel until no resistance is felt. Mix some 30-minute epoxy. Place a sufficient amount of epoxy in each of the hinge pockets in one wing panel. Carefully attach the aileron to the wing, making sure the hinges are inserted in their respective hinge pockets. Press the aileron and wing together until the hinge line gap between the aileron and wing is small enough. Use a paper towel and rubbing alcohol to wipe away any visible epoxy around the hinges. Step 6 Double-check the hinge gap and allow the epoxy to fully cure for enough time. Now is a good time to repeat Steps 1 through 5 for the remaining wing panel and aileron. Step 7 When fully cured, move each control surface throughout its travel range several times to break away any epoxy in the hinge. Be sure to deflect the surface fully. Note: It s a good idea to seal the aileron and elevator hinge lines airtight with a piece of covering to prevent flutter after you finish hinges installation. Section 9 Landing Gear Installation Main landing gear Wheel (2) Wheel pant (left and right) Install the axles in the landing gear. Secure the axles using an adjustable wrench and the nuts provided with the axles. Section 4 Aileron Linkage Installation Control horn linkages (2) Screw the molded swivel link with linkage onto the control horn screw until the distance from the aileron surface to the top of the link is 28mm (1 1/8 ). 14 7
Adjust the linkage length until the hole in the ball link aligns with the outer hole in the servo arm when the aileron is neutral and the servo arm is centered. Attach the ball link to the outer hole in the servo arm with a screw and nut as shown. Don t forget to use threadlock. Step 7 Hinge the rudder using the same techniques as with the aileron and elevator. Step 8 Put the rudder in its neutral position and center the rudder servo. Adjust the length of both rudder cables to match the distance from the rudder servo arm to the control horn. Use a plier to fix the length of the cables. Install the cables on both sides of the outer holes of the rudder servo arm and control horn. Repeat Steps 1 through 3 for the remaining servo in the opposite wing panel. Section 5 Wing Installation Wing panels Wing tube Check the opening for the wing tube, servo leads and pins from inside of the fuselage where the wing panels connect to the fuselage. Carefully remove the covering from the opening using a hobby knife. Locate the wing tube and carefully slide it into one wing panel as deeply as possible. Slide the wing (with tube) into the wing tube opening in the fuselage. Pass the servo lead in the wing into the fuselage before the wing connects to the fuselage. Make sure the wing panel anti-rotation pins slide into the holes provided in the fuselage. Note: It may be necessary to slightly enlarge the holes in the fuselage for the anti-rotation pins using a small round file. Section 8 Tail Wheel Installation Rudder Tail wheel assembly Install the tiller arm to the bottom of the rudder with screws. Position the tail wheel in place as shown, centered on the rear of the fuselage. Using a felt-tipped pen, mark the positions for the mounting screws through the tail wheel bracket. 8 13
Install the rudder servo on the right position of servo tray in the fuselage. Attach the servo arm to the servo. Make sure the servo arm is perpendicular (90 ) to the centerline of the fuselage when the servo is at the neutral position. Put the fuselage on its side with rudder virtually connecting. Using the provided rudder cable, measure a straight line from the rudder servo arm to the opening in, and mark the extension line on the rudder with a pen. Measure rearward 10mm (3/8 ) from the edge of the rudder bevel and make another mark using a pen. The intersection of the line from and this line will be the position for the rudder control horn. Carefully drill through the rudder at the marked position, perpendicular (90 ) to the rudder centerline at the marked position. Be especially careful when penetrating through the backside of the rudder. Step 6 Put the threaded rod of the rudder control horn through the hole and secure it with the provided nuts. Adjust the position of the rod so that it has the same length on both sides of the rudder. Screw the molded swivel link with linkage onto the threaded rod at the right position so that the rudder cable in operation will not hit the opening of the fuselage. Carefully slide the remaining wing panel onto the wing tube that projects from the fuselage. The fit may be tight; use caution when inserting the wing panels onto the wing tube and fuselage. Make sure both wings fit well with the fuselage and there is no gap between them. Secure the wing panels using the provided wing screws. Section 6 Stabilizer Installation Stabilizer (left and right) Stabilizer tube Locate the opening for the elevator servo arm at the bottom of the stabilizer. Carefully remove the covering from the opening using a hobby knife. Install the elevator servo using the hardware provided with the servo as shown. Plug a servo extension onto the servo. 12 9
Center the elevator servo using the radio system. Install a servo arm onto the servo. Note: The technique for installing the control horns in the elevators is similar to the aileron control horn installation. Step 8 Glue the elevator hinges in place using the same techniques used to hinge the ailerons. The shortened hinges will be installed into the stabilizer towards the root. Mark a line 3mm (1/8 ) away from the servo arm and parallel to the movement direction of the servo arm. Measure rearward 10mm (3/8 ) from the top of the elevator bevel and make another mark using a pen. The intersection of the two marks will be the position for the control horn. Carefully drill through the elevator at the marked position. Be especially careful when penetrating through the top surface of the elevator, as it s easy to split out the wood and rip the covering. Placing a wooden block under the elevator and drilling slowly will prevent these problems. Step 9 Install the elevator linkage using the same techniques used to the aileron linkage. 0 Repeat Steps 1 through 9 for the remaining stabilizer and elevator. 1 Install the stabilizer using the same techniques for the wing installation. Secure the stabilizer with screws at the bottom as shown. Note: Make sure to drill the hole perpendicular to the centerline of the elevator. Step 6 From the top of the elevator, plug the control horn screw through the hole and secure it with the provided nut. Section 7 Rudder Installation Step 7 Cut off the first section of one of the hinges. This is done to clear the tube installed in the stabilizer. Rudder Check the opening for the rudder cable in the fuselage. Carefully remove the covering from the opening using a hobby knife. 10 11