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Stevens Aero Model eHopper Instructions Manual

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eHopper
By Stevens AeroModel
Span 33.5 inches | Length 21.5 inches | Wing Area 235 inches
2
| Flying Weight 4.5 - 5.5 oz.
Version 02/02//2010
eHopper
TM
© 2009 Stevens AeroModel all rights reserved.
Page 1 of 36

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Summary of Contents for Stevens Aero Model eHopper

  • Page 1 By Stevens AeroModel Span 33.5 inches | Length 21.5 inches | Wing Area 235 inches | Flying Weight 4.5 - 5.5 oz. Version 02/02//2010 eHopper © 2009 Stevens AeroModel all rights reserved. Page 1 of 36...

  • Page 2: Product Support

    For product assembly support, replacement parts, hardware, and electronics to complete this model please contact Stevens AeroModel on-line at www.stevensaero.com. Stevens AeroModel PO Box 15347 - Colorado Springs, CO 80935 - USA 719-387-4187 - www.stevensaero.com eHopper © 2009 Stevens AeroModel all rights reserved. Page 2 of 36...

  • Page 3: Kit Contents

    Long sanding bar Scissors Razor Plane Electrical Wire Cutter/Stripper Low Tack Painters Masking Tape Straight Edge Ruler 0.025, 1/32, 0.045, and 1/8 in. Drill Bits 2.5mm Allen Head Wrench eHopper © 2009 Stevens AeroModel all rights reserved. Page 3 of 36...
  • Page 4 E-Flite Park 250 [EFLM1130] Motor Mount Tube [EFLM1960] Castle Creations thunderbird 6 ESC GWS 7x3.5 Propellor 7.4V Hyperion 240mAh CX G3 LiPo *Substituting electronics other than specified is not suggested. eHopper © 2009 Stevens AeroModel all rights reserved. Page 4 of 36...
  • Page 5 General Assembly Instructions Thank you, for purchasing this Stevens AeroModel eHopper™. A design inspired by Bill Stevens’ full size Weedhopper. This model has been developed and manufactured using state of the art CAD/CAM systems and features a unique interlocking construction process that, when compared to traditional methods found in other model aircraft kits, save countless hours of measuring, cutting, sanding, and fitting.

  • Page 6: Wing Construction

    Start with left wing. Fit spar S1 to center Fit trailing edge W2 to ribs R1 and R2. rib assembly. Ensure that spar seats snug against R1. Tack glue with thin CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 7 of 36...
  • Page 7 Fit rear spar S2 to ribs. Square wing on Repeat preceding steps and assemble table and bond. NOTE - tip of spar rests right wing to center rib/left wing assembly. ON TOP of wing tip. eHopper © 2009 Stevens AeroModel all rights reserved. Page 8 of 36...
  • Page 8 Install 4-40 blind nut through hole from the top of the rib. Nut may be recessed slightly to facilitate smooth covering. Secure blind nut with thin CA around edges of flange. eHopper © 2009 Stevens AeroModel all rights reserved. Page 9 of 36...

  • Page 9: Tail Feathers

    Fit control approximately 1/32 in. gap between surfaces. horn E6, ensuring that it is perpendicular to elevator. Secure with thin and medium CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 10 of 36...
  • Page 10 Ensure that control horn Open slots for hinges with hobby knife or is square and perpendicular to rudder. Tack razor blade. with thin CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 11 of 36...
  • Page 11 CA. Remove wire. Remove covering from hinge mount area at Assemble vertical stabilizer per plan. base of stabilizer. Do not install hinge at this time. eHopper © 2009 Stevens AeroModel all rights reserved. Page 12 of 36...

  • Page 12: Fuselage Construction

    Left Strut Assembly: With etching on hub F5 (L) facing DOWN, carefully fit Using guide slots in F1b, drill 1/8 in. hole for middle strut F3. Tack glue with thin CA. wing mount. eHopper © 2009 Stevens AeroModel all rights reserved. Page 13 of 36...
  • Page 13 Left Assembly. Seal strut assembly with two coats of Deft. DO NOT SKIP THIS STEP. If not sealed, the ply struts may absorb moisture and warp. eHopper © 2009 Stevens AeroModel all rights reserved. Page 14 of 36...
  • Page 14 CA. Fit upper back rest S5 between sides, ensuring etching faces forward, and tack in place. Fit the other side S1a to seat bottom. Tack glue in place. eHopper © 2009 Stevens AeroModel all rights reserved. Page 15 of 36...
  • Page 15 S2b. at steps with Fit seat struts F7 to side and front as shown. Ensure struts are in the same plane as the base of the seat. Bond with medium CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 16 of 36...
  • Page 16 Fit fender assembly to nose wheel strut. Align Fit two ply sides F8b to ply wheel fork F8a carefully and bond with medium CA. and tack with thin CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 17 of 36...
  • Page 17 Do not bend other end at this point. Cut two lengths of 1/16 in. heat shrink tubing Next, slide seat onto axle. Ensure seat is 1-3/8 in. long to make axle spacers. facing forward! eHopper © 2009 Stevens AeroModel all rights reserved. Page 18 of 36...
  • Page 18 90 degree bend 1/8 in. from one end. plan. Do not bond seat to axle at this time. Trim wire to 3/4 in. length to form front axle. eHopper © 2009 Stevens AeroModel all rights reserved. Page 19 of 36...
  • Page 19 Tack glue rudder hinge assembly to base of Fit vertical stabilizer to slot on bottom of vertical stabilizer. fuselage boom. Ensure stabilizer is aligned with the vertical centerline of fuselage and bond with Medium CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 20 of 36...
  • Page 20 Fit horizontal stabilizer to tabs on F1. Ensure stabilizer. Bond hinge tab at vertical fin with that stabilizer is horizontal and perpendicular medium CA. to rudder. Bond with medium CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 21 of 36...
  • Page 21 Fit struts in holes in stabilizers. Trim to fit if Bond tank to axle and strut assembly with necessary. Ensure vertical and horizontal medium CA. stabilizers remain perpendicular to each other. Bond with medium CA. eHopper © 2009 Stevens AeroModel all rights reserved. Page 22 of 36...
  • Page 22 Mount control stick centered on right axle, Ends of wire should diverge about 45 tilted forward about 30 degrees. degrees. Refer to plan for proper angle. Trim straight portions to 1 in. length. eHopper © 2009 Stevens AeroModel all rights reserved. Page 23 of 36...
  • Page 23 Insert ‘V’ shaped fitting into one long and free, coat shaft of wire with medium CA one short carbon tube. DO NOT GLUE. and insert back to original depth. Tape assembly to drawing on plan. eHopper © 2009 Stevens AeroModel all rights reserved. Page 24 of 36...
  • Page 24 Drill a 1/32 in. hole in each fitting as shown. Mount wing to fuselage using supplied 1 in. nylon bolt and make certain wing is completely seated to fuselage boom. eHopper © 2009 Stevens AeroModel all rights reserved. Page 25 of 36...
  • Page 25 Bond fitting with medium CA. Repeat process with opposite wing. Remove Pass wire through hole in middle strut F3 near wing and struts when finished. main axle. eHopper © 2009 Stevens AeroModel all rights reserved. Page 26 of 36...
  • Page 26 With seat rigging installed we find it helpful to file a small notch where rigging crosses top of fuselage boom to prevent the rigging wire from causing binding when fitting the wing to the fuselage. eHopper © 2009 Stevens AeroModel all rights reserved. Page 27 of 36...
  • Page 27 Secure servos with a small amount of hot glue. NOTE: This motor/gearbox/propellor combination is specific to the power requirements of the eHopper. Other IPS systems with different gear ratios are not suitable. Install Castle Creations Pixie-7P speed Mount...
  • Page 28 Secure all crimps with a drop of medium CA. Rudder Rigging: Trim a control horn as shown for the rudder servo. eHopper © 2009 Stevens AeroModel all rights reserved. Page 29 of 36...
  • Page 29 Center servo, and adjust Cut a length of 1/16 in. dia. carbon rod 11 in. pushrod length by sliding metal fitting in/out of long to make elevator pushrod. heat-shrink sleeve. eHopper © 2009 Stevens AeroModel all rights reserved. Page 30 of 36...
  • Page 30 6 in. wire leads to a 3-pin connector available from StevensAero. Configure color coded wires as shown. Plug lead into receiver. Ensure connector is oriented so black/ground wire is plugged into black/ground socket on receiver. eHopper © 2009 Stevens AeroModel all rights reserved. Page 31 of 36...
  • Page 31 Use outer most hole at control mechanically. Then retain position with a horn. drop of medium CA glue where push-rod, metal, connector, and heat-shrink tube meet. eHopper © 2009 Stevens AeroModel all rights reserved. Page 32 of 36...
  • Page 32 Do not crimp yet. Fix rudder in center position by trapping between two sticks taped together. Attach second wire to left side of control horn. Snug wire but do not crimp. eHopper © 2009 Stevens AeroModel all rights reserved. Page 33 of 36...
  • Page 33 When satisfied that rubber band has proper tension, crimp wire to final length. Mount 7.4V two cell 120mAh battery [HP- Congratulations your eHopper™ is finished! LG325-0120-2s] below the gear box with sticky Velcro (not provided). eHopper © 2009 Stevens AeroModel all rights reserved.
  • Page 34 . When using the Spektrum AR6400 “Puck” you eHopper™ is capable of flying in winds up to will need a computer radio (DX6i, DX7, etc.).
  • Page 35 By now you will have noticed that eHopper™ to the system. respect the business end of is a very stable airplane. When built straight the model (the prop and prop arc) treating and trimmed for level flight, eHopper™...