Download
Share
Print this page
GREAT PLANES Easy Sport 60 Assembly Manual
  1. Manuals
  2. Brands
  3. GREAT PLANES Manuals
  4. Toy
  5. Easy Sport 60
  6. Assembly manual
GREAT PLANES Easy Sport 60 Assembly Manual

GREAT PLANES Easy Sport 60 Assembly Manual

Hide thumbs

Advertisement

Quick Links

Download this manual See also: Instruction Manual
Assembly manual for the Easy Sport 40 and 60
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 BOOK
FIRST. IT CONTAINS IMPORTANT INSTRUCTIONS
AND WARNINGS CONCERNING THE ASSEMBLY
AND USE OF THIS MODEL.
ESP46P03 6/96 V 1 0
WARRANTY
PO Box 788
Urbana Illinois 61801
Entire Contents © Copyright 1996
(217)3988970

Advertisement

loading
Need help?

Need help?

Do you have a question about the Easy Sport 60 and is the answer not in the manual?

Questions and answers

Related Manuals for GREAT PLANES Easy Sport 60

Summary of Contents for GREAT PLANES Easy Sport 60

  • Page 1 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...

  • Page 2: Table Of Contents

    Introduction ...............3 Finish the fuselage..........33 Precautions...............3 Final assembly.............35 Abbreviations ............4 Cut center fairing from fuselage......35 Types of wood............4 Mount wing to fuselage........36 Metric conversion chart..........4 Engine installation..........40 Fuelproof the fuselage.........40 Decisions you must make........4 Install horizontal stab...........41 Engine selection ............4 Install vertical fin ..........41 Landing gear configuration ........4 Mount landing gear..........42...
  • Page 3 Great Planes PT-40 Mkll If you have already learned the basics of R/C flying and can safely handle a basic Your Easy Sport is not a toy, but rather a...

  • Page 4: Metric Conversion Chart

    .70 to 1.20 cu. in 4-stroke tell from most of the photos When important The Easy Sport 40 will f l y well with any of the differences do arise between the 40 and 60, they are recommended engine sizes For "Hot Dogging" and...
  • Page 5 DIE-CUT DRAWINGS Use This Diagram To Locate Die-Cut Parts For The Easy Sport 40.
  • Page 6 DIE-CUT DRAWINGS Use This Diagram To Locate Die-Cut Parts For The Easy Sport 60.
  • Page 7 D HobbyLite" Balsa Filler (HCAR3401) D 12" Silicone Fuel Tubing (GPMQ4131) D Petroleum Jelly D Easy-Touch" Bar Sander and Sandpaper see the Accessories Required to Complete Your Easy Sport 40 following Expert Tip D 2-1/2" Spinner (GPMQ4520) D Dremel MultiPro'" or similar (Optional) D 10oz.
  • Page 8 Note: It is not necessary to get these braces in the exact position shown on the plan If you re building the Easy Sport 40, cut a 1" piece from the 5/16" x 3/4" D 1 Tape the fuselage plan down to your flat work...
  • Page 9 D 6 Using a sanding block and medium (150-grit) D 1 In the same manner as the rudder, build the fin sandpaper, sand the leading edge to a "V-shape" as using the 5/16" x 3/4" and 5/16" x 1/2" balsa sticks shown on the plan Sand the bottom of the rudder to the shape as shown on the plans Sand the trailing edges, bottom edges and top to a rounded shape...

  • Page 10: Precautions

    D 1 In the same manner as the rudder, build each D 6 Trial fit the joiner wire into the elevators Then elevator using the 5/16" x 3/4" and 5/16" x 1/2" glue it in using 6-minute or 30-mmute epoxy When balsa sticks gluing, lay the elevators on a flat surface, with the leading edges along a straightedge to insure perfect...
  • Page 11 power or hand drill Drilling the hole will twist some of the wood fibers into the slot, making it difficult to insert the hinge, so you should reinsert the knife blade, working it back and forth a few times to clean out the slot. INSTALLING CA HINGES The hinge material supplied in this kit consists of a 3-layer lamination of mylar and polyester It is specially made for...
  • Page 12 Glue the 1A sketch) NOTICE: If you feel that any of the wing parts ribs together with thin CA for the Easy Sport 40 Glue are unusable due to severe warps or other defects, give the 1A ribs together with 6-minute epoxy for the us a call and we'll replace the parts.
  • Page 13 D D 2. Lay one of the 3/32" x 1-3/4" x 30" (3/32" x 2" x 32" for the Easy Sport 60) balsa TE sheets on the wing plan, lining it up with the outside edge of the tip rib. Pin in place.
  • Page 14 NOTE: Do not be too concerned if the ribs do not line up exactly with the plan. Sometimes the humidity will cause the plan to expand or contract. Just remember to line up the leading edge, trailing edge and ribs with the outside edge of rib #7 (rib #6 on the Easy Sport 60).
  • Page 15 D D 16. Temporarily pin the wing half back over the plan. On the Easy Sport 40, place the dihedral gauge (DG) on the centerline as shown and mark the LE, front spars, main spars, TE sheeting and TE.
  • Page 16 #1A, 5/8" deep into the LE. D 5. Starting at step 2, repeat for the left wing panel. On both the Easy Sport 40 and 60, slide the spar joiners into the right wing panel first. Slide the left wing panel into place and wipe off any excess epoxy.
  • Page 17 D 9. Securely glue the remaining balsa shear webs to the front and back sides of the spar joiners between ribs #4 and #5 (ribs #2 and #3 for Easy Sport 60). Trim the shear webs so that they do not protrude above or below the spar joiner where they will interfere with the center D 1.
  • Page 18 D 5. Remove the wing dowel from the wing. Mix up a D 7 If you are building the Easy Sport 40, edge glue batch of 30-minute epoxy. Apply the epoxy to the inboard (procedure described below) two of the 3/32"x 3" x side of both die-cut 1/8"...
  • Page 19 D 11. Slide the two die-cut ply aileron servo tray Lt 8. Fit the top center sheet in place on the top of the supports in place. Do not glue them in yet. wing. Its position is aft of the main spar. Trim or sand, if required, for a good fit.
  • Page 20 D 15 On the Easy Sport 40, cut the remaining 3/32" x 3" x 7-1/4" balsa center sheet pieces in half as shown. Custom fit each piece to fit in the four remaining upper and lower forward center sections as shown Glue these pieces securely in place On the Easy Sport 60, custom fit the remaining four 10-7/8"...
  • Page 21 Sections on the plan). Also sand the front and rear corners of the tips to a radius as shown on the plan. D 1. On the Easy Sport 40 locate the four die-cut 1/8" balsa wing tips. Using medium CA as shown, laminate two of the wing tip pieces together.
  • Page 22 D 5. Align each wing half over its respective view on the D 9. Use the sharpened 1/8" diameter brass tube to cut plans and mark the locations of the aileron torque rod bearings and hinges. Using the same technique as a groove in the leading edge of the ailerons to accept slotting for hinges, carefully slot the TE to accept the the torque rods.
  • Page 23 CA. NOTE: On the Easy Sport 40, you can also check the alignment of these parts using a straightedge along the centerline of the assembly.
  • Page 24 D 9. Using medium CA, glue the three die-cut 1/8" ply wing bolt plates (BP) together, aligning the edges D D 6. In the same manner that you assembled the carefully. After the glue hardens, sand the edges to fuse sides, locate and glue together the die-cut 1/8" make them uniform.
  • Page 25 Q 2. If you are going to use the engine mount supplied Clamping the assembly to a table or flat board will with the kit, drill a 5/32" hole through the firewall at each eliminate any warp in the formers. Caution: Check that of the four punch marks.
  • Page 26 D 1. Glue the die cut 1 /8" ply F2A to the die-cut 1/8" F2 as shown To insure proper pushrod routing later, F2A must be glued to the side of F2 that has the embossed "2 " Drill a 3/16" hole at each of the four punch marks on F2, F3 and F4.
  • Page 27 degree triangle to keep it perpendicular to the fuse side. edges with a sanding block and glue them together as shown using medium CA. Sand the glue joints smooth. Glue it in place with thin CA . Make two assemblies. D 6.

  • Page 28: Landing Gear Configuration

    D 10 Place the die-cut 1/8" ply tank floor into the notch in former F2 The tabs on the side of the tank floor will rest in the cut-outs in the fuse doublers as shown Glue the tank floor where it meets F2 only. Depending on the landing gear configuration, trim out the appropriate slots in the balsa fuse sides for the landing gear plate using a hobby knife The aft slot is for...
  • Page 29 D 6. Carefully cut the landing gear doublers on the lines and discard the shaded portions as shown. D 3. Locate the four landing gear doublers (GD) and glue together in pairs using medium CA as shown. Make sure that the slots in the landing gear doublers align. D 7.
  • Page 30 D 2 Test fit, but do not glue, the firewall/tank floor assembly between the fuse sides The rear tab of the D 1. Depending on the landing gear configuration, test tank floor should fit into the notch in F2 and set on the fit, but do not glue, the grooved hardwood landing gear ledge created by the fuse doublers The firewall should (LG) rail in the notches in the bottom fuse doubler The...
  • Page 31 D 7. After the epoxy has fully cured, fit the die-cut 1/8" ply landing gear drill guide into the groove in the landing gear rail (it does not matter which way it goes in). Drill a 3/32" pilot hole through the rail and landing D 4.
  • Page 32 NOTE: You must refer to the proper version in these sketches as you install the pushrod tubes. The following instruction photos apply to the installation of a 2-stroke engine with a tricycle landing gear. D 1. Locate the two 36" outer pushrod guide tubes and scuff the outsides with fine (220 grit) sandpaper.
  • Page 33 Bevel top and bottom of F3A as shown. Not shown to scale. D 2. Locate the two die-cut 1/8" balsa forward fuse bottom halves and glue together in the same manner as step #1. D 3. Locate the two die-cut 1/8" balsa middle fuse top halves and glue together in the same manner as step #1.
  • Page 34 D 10. From the bottom of the fuse, fill the area above the filler plate on the Easy Sport 40 with a piece of D 6. Test fit the front portion of the forward fuse leftover 1/8" balsa. On the Easy Sport 60, use the bottom between the fuse sides.
  • Page 35 D 14. Press the middle fuse top into place between the fuse sides. Glue the middle fuse top to only the fuse sides. NOTE: make sure that no glue gets into the joint between the middle fuse top and the aft fuse top. EASY SPORT .40 HATCH EASY SPORT .60 HATCH D 16.
  • Page 36 D 2. Using a hobby saw and a hobby knife, cut the two die-cut braces from the wing opening on the Easy Sport 40 only. Then, on the Easy Sport 40 and 60, cut the center fairing free from the fuselage following the lines you drew in the previous step.
  • Page 37 the tail) out to a wing tip. Put a piece of tape on the string to mark the intersection of the string and the wing tip. Swing the string over to the other wing tip and check to see if the distances are the same (see diagram). Make slight adjustments to the angle of the wing until the distances from the tail to the tips are equal.
  • Page 38 1/4-20 tap wing and the center fairing Carefully align the center fairing on the wing On the Easy Sport 40, tack-glue D 12 Apply several drops of thin CA to the threads in the the fairing to the wing with a few drops of thin CA Then,...
  • Page 39 D 17. On the Easy Sport 40, trial f i t CFF to the underside TE of the wing and sand if necessary. After fitting, glue in place with thin CA.
  • Page 40 D 1. Cut off the spacer bar from each half of the engine mount, and trim away any remaining bumps to permit the mount halves to slide together D 2. Fit the two halves of the mount together Remove the muffler and carburetor from the engine and install your spinner's backplate Test fit the engine to the mount Adjust the width of the mounting rails to accommodate the engine without binding or being too...
  • Page 41 D 2 Now is the time to fuelproof the front of the model Use fuelproof paint or 30-minute epoxy thinned with alcohol Remove the engine mount and paint the tank floor, fuel tank compartment sides, the bottom of the hatch, the top edges of the fuselage on which the hatch rests, the front and back of the firewall and the engine compartment NOTE Avoid getting the fuelproofer in the D 3 Attach the wing to the fuse (for reference) and...
  • Page 42 (not included). D 2. On the Easy Sport 40, fit the two 3/16" main landing gear wires in place on the fuse bottom. Slide the two die-cut 1/8" ply LG aligner strips in place fore and aft of the main landing gear.
  • Page 43 D 7. On the Easy Sport 40, align the threaded hole in one 5/32" wheel collar with the small hole in the side of the nylon steering arm. Keeping this alignment, press the wheel collar into the nylon steering arm. On both the Easy Sport 40 and 60, thread the 6-32 x 3/16"...
  • Page 44 Cut out any clearance holes or notches you marked in the previous step Be sure to provide sufficient clearance to allow easy fingertip adjustments of the needle valve Remount the components removed from the engine Mount the engine to the engine mount and cut the fuel supply and muffler pressure lines to length.
  • Page 45 D 3 On the Easy Sport 40, glue the servo tray and the die-cut 1/8" ply servo tray support (STS) securely in place with medium or thick CA Add thick CA along the joints to lock the tray in place...
  • Page 46 Clevis and Retainer D 9. Slide a silicone retainer onto the rear end of a nylon clevis. Thread the nylon clevis 13 revolutions onto a 36" wire pushrod (threaded on one end). With the rear of the model facing you, slide the pushrod into the right hand pushrod tube until the clevis pin is even with the elevator hinge line.
  • Page 47 Blue, Dove Grey and Missile Red The trim colors were sealed Use a Top Flite MonoKote Hot Sock" on your bordered with Great Planes 1/16" Black Kwik Stripe" covering iron to avoid scratching the MonoKote. Model Striping Tape...
  • Page 48 MonoKote film for your trim on the technique described in the "Install The Aileron Torque Easy Sport 40, ask your hobby dealer for the Great Rods section of this manual Don t forget to apply a little...
  • Page 49 We masked all of the sections of the canopy we wanted to remain clear and then sprayed the exposed framework with K&B Epoxy Paint Rather than painting, you may apply Great Planes Kwik Stripe Model Striping Tape directly over the canopy framework The choice is yours Apply 1/16"...
  • Page 50 2 On the Easy Sport 60, locate the servo tray at the position shown on the plans On both the Easy Sport 40 Reinstall the engine, muffler, propeller, spinner, battery, and 60, attach the wing to the fuselage With an empty...
  • Page 51 Make sure the control surfaces move in the proper direction. CARBURETOR WIDE OPEN We recommend the following control surface throws for the Easy Sport 40: NOTE: Throws are measured at the widest part of the elevators, rudder, and ailerons HIGH RATES...

  • Page 52: Spars

    Follow the battery charging procedures in your radio NOTE: Failure to follow these safety precautions instruction manual You should always charge your may result in severe injury to yourself and others. transmitter and receiver batteries the night before you go flying, and at other times as recommended by the radio Keep all engine fuel in a safe place, away from high manufacturer.

  • Page 53: Radio Control

    The Great Planes Easy Sport is a great flying sport (Excerpt) airplane that flies smoothly and predictably, yet is highly Read and abide by the following Academy of Model maneuverable It does not, however, have the self-recovery characteristics of a primary R/C trainer;...

  • Page 54: Landing

    Have a ball, but always stay in control and fly in a safe manner. GOOD LUCK AND GREAT FLYING! SEE THE FULL LINE OF GREAT PLANES AIRPLANES AND AIRPLANE ACCESSORIES AT YOUR HOBBY DEALER. WE HOPE YOU WILL SELECT ANOTHER "GREAT PLANE"...

  • Page 56: View Drawing

    2-VIEW DRAWING Use This Diagram To Plan Your Trim Scheme. Use copies of this page to plan your trim scheme...