GREAT PLANES CAP 232 Instruction Manual
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GREAT PLANES CAP 232 Instruction Manual

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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
AND USE OF THIS MODEL.
CAP4P03 V1.0

INSTRUCTION MANUAL

WARRANTY
P.O. Box 788
Urbana, IL 61801
www.greatplanes.com
(217) 398-8970
Entire Contents © Copyright 1998

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Summary of Contents for GREAT PLANES CAP 232

  • Page 1: Instruction Manual

    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.

  • Page 2: Table Of Contents

    CAP through its paces. Charge the Batteries ............41 When you have a feel for your CAP 232, the throws can be Balance the Propeller...........41 increased to high rates (illustrated in the instructions) to...

  • Page 3: Decisions You Must Make

    On our prototype CAP 232 with the O.S. .46FX we used the Slimline #3218 Product info – www.greatplanes.com Pitts Muffler (SLIG2218) without the exhaust extension kit. If E-mail –...

  • Page 4: Building Supplies & Tools

    Drum, Cutting Burr, Cut-off Wheel Kyosho ® Curved Scissors for trimming Cowl, Wheel Pants and Canopy (KYOR1010) In our busy work shop we use the Great Planes Easy-Touch ™ Bar Sanders equipped with Great Planes #80, #150 and #220-grit Easy-Touch Adhesive-Backed...

  • Page 5: Building Notes

    Building Notes Common Abbreviations There are two types of screws used in this kit: Elev = Elevator Fuse = Fuselage Sheet metal screws are designated by a number and LE = Leading Edge (front) LG = Landing Gear a length. Ply = Plywood Stab = Stabilizer For example #4 x 3/4"...

  • Page 6: Die-Cut Patterns

    DIE-CUT PATTERNS...

  • Page 7: Die-Cut Patterns

    DIE-CUT PATTERNS...

  • Page 8: Build The Tail Surfaces

    BUILD THE TAIL SURFACES Build the Stab 1. Cover the stab portion of the plan with wax paper or 5. Using medium CA, glue one 1/16" x 3" x 24" balsa Plan Protector. Pin the die-cut 1/8" balsa stab LE doubler sheet to one side of the stab framework, aligning the in position over the plan.

  • Page 9: Elevator Building Sequence

    Elevator Building Sequence Rudder Building Sequence A. 1/4" x 1/2" LE B. 1/4" x 1/2" Rudder bottom C. 1/4" x 1/2" TE D. Two 1/4" x 1/2" ribs E. One 1/4" x 1/2" diagonal rib F. Two 1/8" x 1/4" diagonal ribs Remove the rudder from your building board and sand the top, the LE and TE so they are flush.

  • Page 10: Finish The Tail Surfaces

    B. Flip the stab over and mark another line in the same location Finish the Tail Surfaces as the first. If you see only one line, then it is on center. Proceed and mark the hinge slots at each hinge location. If you see two lines you will have to adjust the height of the stab until you can 1.

  • Page 11: Build The Wing

    HOW TO MAKE WING SHEETS A. Use a metal straightedge as a guide to trim one edge of both sheets. 3. Use the plan to make sure the balance tabs are properly aligned. Then, using medium CA, glue the balance tabs to both of the elevators and the rudder.

  • Page 12: Build The Wing Panels

    top spar. Cross pin the tip of the spar to the plan with a piece of 3/32" leftover balsa under the spar past the location of rib R-10. 2. Place (do not glue) the die-cut 3/32" balsa wing ribs R-2 through R-10 on the top spar over their locations on the plan.
  • Page 13 Mark the root end so that it lines up with the centerline of the wing. Take the TE off your work bench and sand the TE to the mark you made. 5. Glue the main spars to the ribs with thin CA. As you glue each rib to the spars, simultaneously pull the top spar up into the rib and push the bottom spar down into the rib to make sure the spars are fully seated in the notches.
  • Page 14 12. Before you glue the LE sheeting in position, remove the T-pins from the front jig tabs in the wing ribs. 17. Using a razor saw, trim the spars, LE, TE, LE sheeting, and TE sheeting flush with R-10. Also trim the LE and LE sheeting flush with the edges of R-2.

  • Page 15: Join The Wing Panels

    Join the Wing Panels Note: The designer wishes to assure you that the specified dihedral is correct. Although somewhat out of scale, this dihedral angle is required to eliminate roll coupling, thus providng you with a more neutral airplane. A side benefit of the dihedral is better low speed stability.

  • Page 16: Sheet The Wing

    Sheet the Wing 6. Cut pieces from a 3/32" x 3" x 30" balsa sheet to cover the middle portion on the top and bottom of the wing. 1. Use medium CA to glue the die-cut 1/8" ply aileron servo tray and supports in position. Glue the die-cut 1/8" ply aileron servo tray doublers to the bottom of the aileron servo tray.
  • Page 17 7. Cut the aileron approximately 1/16" shorter than the mark you made at the tip so it will fit in the wing. 2. Place the center TE's over the wing plan and mark the location of the aileron torque rods. Cut notches at the marks to clear the torque rods.

  • Page 18: Build The Fuselage

    BUILD THE FUSELAGE Assemble the Fuse Formers & Sides B. Use the sharpened tube to carefully gouge the leading edge of the aileron. You'll have to make a few cuts to make the recess deep enough for the torque rod. 11.
  • Page 19 3. Lay the other fuselage side next to the right side as 7. Draw center lines connecting the outer punch marks shown in the photo and label it on the inside as the LEFT. on the firewall. Drill 5/32" holes for the engine mount bolts It is important that you lay the fuselage sides in a mirrored at the four engine mount punch marks.

  • Page 20: Assemble The Fuselage

    Assemble the Fuselage Note: The interlocking construction this Great Planes kit allows you to quickly assemble the fuselage upside down on the plan while maintaining alignment. You will be fitting most of the die-cut fuselage parts together before applying glue. Do not use any glue until instructed to do so.

  • Page 21: Mount The Wing To The Fuselage

    8. Glue the fuse sides to the fuse top and bottom with thin Mount the Wing to the Fuselage CA. Leave the fuse assembly pinned to your work surface. 1. Sand the entire wing saddle area lightly until the fuse side doublers and fuse sides are flush.
  • Page 22 5. Slightly round one end of a 1/4" x 1-1/8" wing dowel. 8. Now that the wing is accurately aligned, glue the wing Using 6-minute Epoxy, glue the dowel in the wing leaving bolt plate in place on the wing, being careful not to glue the 3/8"...
  • Page 23 13. Glue the 1/4" ply landing gear rail in position with 6-minute epoxy. 16. Install 8-32 blind nuts supplied with this kit into the landing gear rail from inside the fuselage. Use the 8/32" x 3/4" socket head cap screws through the landing gear to pull the blind nuts into position.
  • Page 24 21. After the filler has fully dried, remove the wing from 26. Glue the stab base in place with thin CA. the fuselage. Cut and sand the spacers and the filler to match the contour of the wing. 22. Cut a 36" plastic outer pushrod tube in half, making two 18"...

  • Page 25: Build The Front Fuselage Deck

    30. Sand the fuselage sides flush with the firewall. Sand the bottom of the firewall flush with F1C. Sand the bottom of F1C flush with the landing gear base. Build the Front Fuselage Deck Note: The front and the rear of the front deck use the same 4.

  • Page 26: Mount The Stabilizer To The Fuselage

    11. Use your bar sander and 150-grit sandpaper to sand the sides and top of the front deck sheeting so they are even with the fuse sides. Trim the ends of the sheeting so they are flush with both F-2's. 12.

  • Page 27: Build The Turtledeck

    4. Place the stab on the stab base with the center marks 2. Use a square to position and glue the die-cut 1/8" ply aligned, then use a large T-pin to pin only the trailing edge formers F-6, F-9, and F-10 vertically, at 90 degrees to the of the stab to the stab base.
  • Page 28 5. Edge glue three 3/32" x 3" x 18" balsa sheets together, making a 9" x 18" sheet. 14" 1-1/16" 5-1/4" 9. Now that the sheeting has conformed to the turtle deck shape, trim the top edge so that the sheeting fits tight against the gluing stringer.

  • Page 29: Mount The Engine

    Mount the Engine 1. Cut the "spreader bar" from the supplied Great Planes engine mount, then use a hobby knife to remove any flashing left over from the molding process so the halves fit together well. 2. Temporarily mount the engine mount to the firewall with four 6-32 x 1"...

  • Page 30: Install The Battery & Tank

    HOW TO ACCURATELY MARK AND DRILL THE ENGINE MOUNTING HOLES ON THE ENGINE MOUNT A. Use C-clamps to hold the engine in position. 2. Attach the battery and the tank to the die-cut 1/8" tank floor (TF) with nylon tape as shown in the photo. Make sure the embossed label TF is towards the tank.

  • Page 31: Install The Servos And Make The Pushrods

    5. Install the die-cut 1/8" ply tank hatch with two #2 x 3. Place the throttle servo in the servo tray. Temporarily 3/8" sheet metal screws. install the brass Screw Lock Pushrod Connector into the throttle servo arm, then adjust the bend in the throttle pushrod if necessary and fit it into the connector.
  • Page 32 6. With the elevator servo set in place, the servo control horn centered and the control surfaces in their neutral 10. Mount the rudder servo in the fuse as shown. Mount position, use a felt tip pen to mark where the longer the 2-56 ball link to the rudder servo arm with the 2-56 nut pushrod crosses the mounting holes in the servo arm.

  • Page 33: Add The Forward & Aft Wing Fairings

    13. Reattach the servo arm with the pushrod to the ser vo. Mount the control horn the same way as the elevators with two 2-56 x 5/8" screws. 14. Mark the location of the tail gear wire on the rudder and the nylon tail gear bearing on the fuselage.

  • Page 34: Assemble The Wheel Pants

    2. Use your bar sander to carefully true the edges of the overlapping pieces of the wheel pant halves so when you glue them together the seam will be as small and straight as possible. Notice that the front and rear of the pant halves do not overlap and are "butt glued"...
  • Page 35 C. Use a 9/64" hex wrench to screw the axle through the wheel and the wheel pant until the wheel goes all the way 8. Drill a 3/16" (11/64" or #18 for precision) hole in in and the axle goes through the pant mount. the wheel pant at the mark.

  • Page 36: Assemble The Cowl

    Assemble the Cowl 1. The cowl is assembled in a manner similar to the wheel pants. Cut the cowl along the cut lines, then use your bar sander to true all the edges. For now, the opening in the front cowl piece only needs to be roughly cut out. Use coarse sandpaper to roughen all the overlapping areas so the glue will stick.

  • Page 37: Prepare The Model For Covering

    the fuse, then proceed to cover the fin and stab with pre-cut pieces that meet in the corners and overlap the 1/4" strips. Never cut the covering on the stab and fin after it has been applied except around the leading and trailing edges and at the tips.

  • Page 38: Balance The Model Laterally

    BALANCE THE MODEL LATERALLY FINAL HOOKUPS & CHECKS Do not confuse this procedure with "checking the Join the Control Surfaces C.G." which will be discussed later in the manual. Now that the model is covered and nearly competed, this is the time to balance it laterally (side-to-side).

  • Page 39: Install The Hardware

    4. Install the elevator, rudder and throttle pushrods and ASSEMBLE, THEN APPLY 6 DROPS servos. Install the control horns and hook them up the OF THIN CA TO CENTER OF HINGE, ON BOTH SIDES same way you did earlier. THE CA WICKS ALONG THE "TUNNELS"...

  • Page 40: Set The Control Throws

    If, after you become comfortable with and dries overnight (to allow for accurate positioning). your CAP 232, you would like to adjust the throws to suit your tastes, that's fine. Too much throw can force the plane into a stall or snap, so remember, "more is not better."...

  • Page 41: Preflight

    CAP 232, you may wish to experiment by shifting the damage your radio receiver and battery. Vibration may balance up to 1/4" forward or back to change the flying cause your fuel to foam, which will, in turn, cause your characteristics.

  • Page 42: Range Check The Radio

    full power, and maintains full power indefinitely. The engine Use a "chicken stick" or electric starter; follow instructions must be "broken-in" on the ground by running it for at least supplied with the starter or stick. Make certain the glow two tanks of fuel.

  • Page 43: Flying

    Check all servo grommets for deterioration (this may We recommend that you take it easy with your CAP 232 for indicate which surface fluttered), and make sure all the first several flights, gradually "getting acquainted" with pushrod linkages are slop-free.

  • Page 44: View Drawing

    2-VIEW DRAWING Use this layout for trim scheme planning only. Not suitable for scale documentation.

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