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Gruner F5J Assembly Manual
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Gruner F5J Assembly Manual

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Original work in German by GRÜNER CNC Service, all rights reserved 2015.
This version is published with the expressed permission of GRÜNER CNC Service.
Download the
original document
Translation to English by the following contributors:
● Fabien Gagné (FabFlight), Canada
● Christopher Kerrigan (Cricklewood), Canada
● Dario Ernst (NebuK), Karlsruhe, Germany
● Anthony Eden (aerotony), Australia
Grüner can not be held liable for consequential damages that may arise during the operation
of products from our product range.
Observe all notes intended for use (addendum).
No liability for misprints.
The reproduction of texts and text extracts, drawings and pictures is only allowed with our
express written permission.
Introduction F5J
Assembly Manual
herewith full illustrations.

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Summary of Contents for Gruner F5J

  • Page 1 Introduction F5J Assembly Manual Original work in German by GRÜNER CNC Service, all rights reserved 2015. This version is published with the expressed permission of GRÜNER CNC Service. Download the original document herewith full illustrations. Translation to English by the following contributors: ●...
  • Page 2 Building instructions Thank you for choosing a quality product MADE IN GERMANY. Please read these building instructions and suggestions prior to construction, then carefully proceed with the step by step construction. PRESENTATION OF THE MODEL The wings are constructed in three sections with carbon tube spars. The wing joiners are built into the spars.
  • Page 3 Sheet 72.08 Parts H1H8 ● Cut out the plan and cover with transparent film (cling wrap film or polyethylene). ● Glue together the tailplane parts H1 to H8 (thick CA). Sheet 72.08 Parts H9- Check the fit of diagonal braces H9 to H12 and glue into place without warping theframe ●...
  • Page 4 Sheet 72.13 Part H28 NOTE:This step is only required if building a removable elevator. Glue ply pieces H28 in the holes of the centrepiece H3(thick CA). ● Sheet 72.08 Parts H13- ● Glue the elevator parts H13H20 (thick CA). ● Check fit then glue the diagonal braces H21 to H25 without warping the frame(thick CA).
  • Page 5 Sheet 72.13 Part H26 ● Figure 1. Glue together (stack) the two plywood elevator connectors H28(thick CA). ● Figure 2 and 3. Glue the connectors to the centre of the elevator(thick CA). ● Figure 4. Sand the tailplane and elevator according to thesections shown on the plan.
  • Page 6 Sheet 72.07 Parts S8- ● Glue the rudder parts S8 to S16 (thick CA). Sheet 72.07 Parts S17- ● Check fit then glue the diagonal braces S17 to S22 without warping the frame(thick CA). ● Sand the rudder to the sections shown on the plan.
  • Page 7 Sheet 72.02 Parts R1,R2 NOTE:In the following phases be sure to make one lefthanded and one righthanded fuselage side. ● Glue the front and rear side portion of the fuselage walls R1 and R2 (thick CA). Cut out/file out the slots for the pushrod sleeves in the lefthand fuselage side infront of ●...
  • Page 8 Sheet 72.14 Parts R6,R7 Glue the wingbed doubler R6 and front fuselage doubler R7 flush with the fuselage edge ● (thick CA). Sheet 72.05 Parts R8- ● Glue the stiffeners R8 to R17 (thick CA). ● NOTE:Pay attention to the orientation of the slots in R12 to R16 (to accept the fuselage stiffeners R23 to R27 in step 19).
  • Page 9 ● Clamp both panels together and sand the outer edges. Sheet 72.13 Parts R18, R19, R21 Small parts bag Part ● Align and glue together (stack) both R21 parts using clamps (thick CA). ● Align and glue together (stack) R18 and R19 using clamps (thick CA). ●...
  • Page 10 Sheet 72.14 Parts R20 ● Glue the wing saddle R18/R19 at right angle (5 minutes epoxy). ● Glue the R20 and R21 ribs exactly perpendicular (thin CA). ● Glue the second fuselage sidewall assembly. Use the same adhesives as in step 15. ●...

  • Page 11: Table Of Contents

    Sheet 72.16 Part R22 ● Glue the nose block R22 (thin CA). ● For this purpose make the fuselage with nose block perpendicular to a surface and apply the adhesive on the inner surfaces of the side parts. ● The adhesive can penetrate the nose block, so perform this task installed over a plastic film.
  • Page 12 Sheet 72.05 Parts R23- ● Glue the pushrod sleeve guides R23 to R27 into the slots in R12 to R16 (thin CA). Use the plan, protected by transparent film, as a guide to ensure that the fuselage is straight and that the fuselage sides are vertical. ●...

  • Page 13: Part R22

    Small parts Part R29 ● With a thin round file (mouse tail file) or a 2 mm drill bit, rework the slots for the pushrod guide tubes. ● Install the guide tube R29 and check the smooth running of the pushrod wire R56. ●...

  • Page 14: Sheet 72.01

    Sheet 72.01 Parts R30- ● Glue bottom fuselage sheeting (parts R30 to R39) (thick CA). ● Adjust the cutout for the rudder on part R39 to the fit the rudder. Sheet 72.01 Parts R40- ● Glue the top fuselage sheeting parts R40 to R48 (thick CA). ●...
  • Page 15 Sheet 72.01 Parts R53a, R53b Sheet 72.14 Part R54 ● Glue the doubler of the battery flap R53.2 exactly centered on the part R53.1 (thick CA). ● Glue the siderails, R54 on both sides of R53 (thick CA). The battery hatch cover should fit easily into the fuselage cutout. Sheet 72.01 Parts R49- Long parts...

  • Page 16: Part R28

    Sheet 72.13 Part R55 ● Screw the motor to the motor bulkhead R55. ● Wrap the motor in several layers of paper so that it fits snugly into the nosepiece. This will ensure that the motor is centered and that the motor will turn freely after gluing the bulkhead.
  • Page 17 Sheet 73.03 Parts F4 Small parts Parts F5, ● Glue one F4 to one of F6 rib each, making sure it is flush (thick CA). The locking pin F68 can be used as a guide but do not glue F68 into place. Fasten the latch F5 with a little glue (thick CA).

  • Page 18: Parts

    Sheet 73.03 Parts F7F9, Sheet 73.11 Part Long parts bundle Part F1 ● Dryfit the rib combination F6/F4/F6 and all ribs labeled F7, F8, F9 and F11 onto the spar tube F1, according to the plan. ● Insert the servo frame F10 between the ribs F8 and F9. Sheet 73.10 Part F12 ●...
  • Page 19 Long parts bundle Part Sheet 72.03 Parts F14 ● Glue in the leading edge F13 (thin CA). ● Glue in the half ribs F14 (thin CA), aligning them carefully over the plan. Sheet 72.09 Parts F15, NOTE:All reinforcements are glued flat down on the plan. ●...
  • Page 20 ● Plane the trailing edge to match the profile of the ribs (airfoil) and sand carefully. ● Cut away the excess (length) of the leading edge F13 (the black rod)and the spar (the carbon tube) with a fine metal saw carefully, and sand completely flush. Sheet 73.13 Parts F72- Glue together the servo covers from parts F72, F73 and F74 (thin CA).
  • Page 21 Sheet 73.12 Parts F22 Sheet 73.04 Part F23 ● Glue the connecting rib F23 between two F22 ribs. Clamp to straight board until the glue sets (thick CA). NOTE:This can be done in one or two stages. NOTE:Pins F68 can be used to align the pieces together but do not glue into place at this time.
  • Page 22 Sheet 72.04 Parts F24- ● Thread the ribs F24 to F31 to the spar F21 ● Fasten the end bar F33 to the plan ● Ajust the ribs to the end bar and glue the at right angle to the spar Sheet 72.05 Parts R23- ●...
  • Page 23 Long parts bundle Part F13 Sheet 72.03 Parts F34- - Glue the leading edge F13 to the ribs. - Glue the half ribs F34 to F39 to the leading edge and the spar. Sheet 72.11 Parts F44 Grind the end sprits F44 at the rear edge to the marking line ●...
  • Page 24 Long parts bundle Part F43 Sheet 72.04 Parts F45- ● Dry fit and slide ribs F46 to F54 onto carbon fiber spar. ● The ribs will then correctly match the angled slots in the upper face of F44. ● Align and glue all ribs to the trailing edge strip (thick CA). ●...
  • Page 25 ● Figure 1 For all surfaces parts sand the ribs gently to the blend in with the trailing edge. ● Figure 2 3 Sand spar tubes and leading edge flush with the end ribs. Part F46 Sheet 72.04 Parts F45- ●...
  • Page 26 Long parts bundle Part F43 Sheet 72.04 Parts F45- ● Sand and/or plane the wingtip flush with the top of the rib. Use the aileron, F86, as a guide. ● Glue the wing tip F70 flush with the bottom edge of the outermost wing part. ●...
  • Page 27 Small part Part F20 Sheet 72.09 Parts F17 ● Figure 1 Sand (roughen up) and degrease the brass tube F20. ● Figure 2 Slide the brass tube carefully into the holes in the wing joiner until the angled/skewed side is flush. ●...
  • Page 28 Sheet 72.12 Parts F64, Small parts bag Part Sheet 72.04 Part F66 ● Figure 1 Shows the joiner for the outer wing sections. Glue parts F64 (2 pieces) and F65 (2 pieces) together (thick CA). ● Figure 2 Sand (roughen up) and degrease the joiner rod where it will be glue. Slide the joiner rod into the hole in the wing joiner tube, ensuring that it is correctly aligned.
  • Page 29 ● Figure 4 Apply glue to the faces of ribs F45 and F32 and the edges of the connector F71 that fit into spar F21 (90 minutes epoxy) and slide the wing sections over the wing connector, removing excess glue. Clamp ribs F45 and F32 until the epoxy sets. ●...
  • Page 30 tube F1, sealed edge first (90 minutes epoxy). Remove excess glue. ● Figure 3 Align the spar tube assembly flush with the connecting rib and perpendicular using the tape to hold it in place. Leave to dry, and then remove the tape. Small parts Parts F68 ●...
  • Page 31 Rudder COVERING : In the method described here, the covering is applied through the hinge in one piece, which eliminates the need for a separate hinge. ● Cut two pieces of covering, one for each side of the rudder with about 2 cm overhang. ●...
  • Page 32 ● The covering for the wing parts can be made in one piece. This saves attaching the covering to the thin leading edge. ● The flaps and hinges, as with the tail surfaces, can be covered as one piece with the wing.
  • Page 33 ● Fold the covering over the leading edge and iron the covering to the trailing edge and onto the flaps. ● Iron the covering to the lower part of the root ribs, and cut off with 3 mm overlap ● Shrink covering starting from the center, starting either from top or bottom. It is important that the covering has thorough adhesive contact to all ribs before shrinking.
  • Page 34 Fuselage ● First, cover the sidewalls of the fuselage ● Cut covering for the sides of the fuselage with a 5 mm overlap at the top and bottom and a 2mm overlap/projection on the front. Iron the covering on including the overlap on the sides and the front.
  • Page 35 Sheet 72.17 Parts F78, F88,H27, S23 ● Cut slots in the covering material for the horns on the control surface. ● Sand the horn’s tabs as shown in the figures (red circles). ● Insert into the slots and glue the horns F78 (spoilers) and F88 (aileron inside and outside) (thin CA).
  • Page 36 Long pieces bundle Parts R56 Small parts bag PartsR58, R59, R60, F76 ● Attach servos to the servo frames. ● Make servo linkages from the remaining of the servo rods R56, clean ends and solder on a threaded coupler R59, then add nut R60 and clevises R58. Adjust servo arm and linkages to fit the appropriate control surface.
  • Page 37 Aligning empennage and wings Throws, center of gravity and flying Control surface throws ● Elevator +/ 15 mm ● Rudder +/ 60 mm ● Flaps 70-90 degrees ● Thermals: flaps 2 mm down ● Speed: flaps 2 mm upwards Center of Gravity (CG): ●...