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AMR 25% Super Decathlon Assembly Instructions Manual

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-AMR 25% Super Decathlon-
Building manual
-96'' wing span---64 ½'' fuselage---1 488 Sq. In.---35/50cc engine-
www.amr-rc.com
October 24, 2012

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Summary of Contents for AMR 25% Super Decathlon

  • Page 1 -AMR 25% Super Decathlon- Building manual -96’’ wing span---64 ½’’ fuselage---1 488 Sq. In.---35/50cc engine- www.amr-rc.com October 24, 2012...

  • Page 2: Warranty

    -Warranty- Aircraft Modelers Research Incorporated guarantees this kit to be free from defect 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 Aircraft Modelers Research’s liability exceed the original cost of the purchased kit.
  • Page 3 Introduction Thank you for purchasing AMR product. AMR (Aircraft Modelers Research) prides itself on bringing you the finest aircraft model kits due to our team efforts and our state of-the-art equipment that affords exceptional quality. Using CNC driven production equipment, each of our kits is individually laser-cut according to plans which includes custom fittings and hardware sets specific to your model.
  • Page 4 Before you begin, important notes from A.M.R 1-) This model airplane is not a toy. It must be built with outmost care. It is imperative that you follow each steps of the building manual. If you need assistance of any kind, please contact us directly. 2-) Adhesives: a-) For general assembly, wood glue works best.
  • Page 5 Balance your plane carefully. Use servos that provides sufficient torque and high power batteries to fly this aircraft. Recommended engines: Any good 30 to 50CC engines are suitable for this plane. It is strongly recommended to stay within this range. Failure to follow this recommendation may damage the airplane since it is not design for larger engines.
  • Page 6 A.M.R 25% Decathlon hardware list Description Quantity Description Quantity Tailwheel bracket 4-40 x 1/2'' Cap screws Servo Lead tubes/48'' long 4-40 x 3/4'' Cap screws Robart 3/16'' Hinge points 4-40 x 1 1/4'' Cap screws Robart 1/8 " Hinge points 4-40 x 1 1/2'' Cap screws Wheels 6-32 x 5/8'' Cap screws...
  • Page 7 A.M.R 25% Decathlon wood list Description Quantity 1/8'' x 1/2'' x 48'' Balsa sticks 1/8'' x 1/2'' x 48'' Balsa sticks 1/8'' x 4'' x 48'' Balsa sheets 1/4'' x 1/4'' x 36'' Balsa sticks 1/4'' x 3/8'' x 48'' Balsa sticks 3/8'' x 3/8'' x 36'' Balsa sticks 3/8'' x 1/2'' x 24'' Balsa sticks 1/2'' x 1'' x 48'' Balsa sticks...
  • Page 8 NOTICE TO BUILDER: Working Surface: A flat surface at least 24 X 72 inches is require to build this model. It is important the surface is flat to guaranty straight building. Wood : After removing parts from the laser cut plywood and balsa, it is highly recommended to keep some scrap pieces for later use during the build.

  • Page 9: Fuselage Assembly

    FUSELAGE ASSEMBLY Follow directions carefully Always dry fit first Assemble all components on a flat building board...
  • Page 10 STEP1 1-install on a flat building surface a sheet of waxed paper 2-Dry fit FC1A and FC1B to make sure it fit properly. Notice door location should be on the left side since the fuselage is build from the bottom 2-Once fit is found correct, apply glue to join both parts as shown.
  • Page 11 STEP3 1-Dry fit STEP2 assembly on F1 to make sure it fit properly. 2-Once fit is found correct, apply glue to join both parts as shown. 3-Cut (2) 1/2 triangular hardwood sticks 3 inches long and glue behind F1 as shown 5/8 triangular stick on both sides...
  • Page 12 STEP4 1-Install (2) 6-32 blind nuts and apply glue around nut flanges 2-Dry fit F31 to F2A and F3A. Once fit is found correct, apply glue to join both parts as shown. 6-32 BLIND NUTS STEP5 1-Glue F23 over F22 and make sure to align holes properly. Notice that F23 is wider than F22. 2-Glue F24 over F23 and make sure to align holes properly.
  • Page 13 STEP6 1-Install (2) 6-32 blind nuts and apply glue around nut flanges 2-Dry fit F31 to F2A and F3A. Once fit is found correct, apply glue to join both parts as shown. NOTICE: 2 BLIND NUTS ROW NEAR F2 STEP5 ASSEMBLY STEP7 1-Dry fit first.
  • Page 14 STEP8 1-Dry fit (2) FS and (2) F10 to assembly as shown 2- Glue both parts as shown. Trim 1/4sq balsa STEP9 to fit 3/8 sq stick 1-Glue (2) 3/8 sq balsa 28in long on rear of fuselage 2-Fit and glue ¼ sq balsa as shown 1/4sq balsa sticks 3/8sq balsa sticks Top view...
  • Page 15 STEP10 1-Dry fit FB over assembly as shown 2- Glue FB as shown. STEP11 1-Dry fit and glue STEP4 assembly, F4A and F5A as shown STEP4 assembly (F2A, F3A and F31)
  • Page 16 STEP12 1-Cut (2) 1/4 X 3/8 28 inches long balsa sticks 2-Glue sticks as shown between F3A and F6 as shown. Trim excess flush with F3A. 1/4 X 3/8 balsa sticks STEP13 1-Use F11 to mark line on 3/8sq balsa stick and remove material 1/8 deep as shown prior installing F11 and F11A Use F11 over 3/8 stick to mark line and remove material 1/8 deep...
  • Page 17 STEP14 1-Install (2) 4-40 t-nuts under F11A as shown 2-Glue F11A flush with balsa cut-out made at step 13 as shown. T-nuts must be inside. F11A F11A STEP15A 1-Glue F11 over F11A. Glue 1/4 dia dowel 2-Drill 1/4 dia hole in 3/8 balsa at 1 ¾ inch from existing hole And drill 5/64 dia hole in center (use tail wheel to locate the hole properly) 3-Glue 1/4 dia dowel 3/4 inch long...
  • Page 18 STEP15B 1-Cut and glue 3/8sq sticks to brace rear of fuselage bottom as shown 2-Cut and glue 3/8sq balsa sticks to brace sides of rear fuselage as shown as shown.
  • Page 19 STEP16A 1-Move fuselage so that the front end is a bout an inch in front of building table. 2-Dry fit first and glue F1 assembly (step2) to fuselage assembly as shown. 3-Cut (2) 1/2 triangular hardwood sticks 5 inches long and glue them inside fuselage as shown on both sides. STEP2 assembly (F1) Glue 1/2 triangular hardwood both sides...
  • Page 20 STEP16B 1-Glue (2) F13A inside fuselage (one on each sides). F16A must contact F2 and the ¼ sq balsa stick located on the bottom of the fuselage 2-Cut (2) 3/8 X ½ X 7 11/32 inches long hardwood sticks and glue them in slot found in F13A as shown. 3-Locate F13 over the hardwood block and drill 4 holes in hardwood stick using holes found in F13 4-Use (4) No2-1/2 long screws to secure F13.
  • Page 21 Throttle and choke servos installation NOTE: It is highly recommended to install these servos prior completing the sheeting. Since F13 is removable, Battery can be located under F13 in order to balance the plane This servos installation is suggested but can vary depending on engine type and builder choice It is also recommended to use velcro tape under ignition to help to maintain it in place and to reduce vibration.
  • Page 22 STEP17 1-Glue (5) 3/8sq balsa sticks between F1 and F2A as shown. 2-Sand flush at both end. 3-Sand to match F1 and F2A shape 3/8 balsa sticks PHOTO SABLAGE ICI. STEP18 1-Glue (1) F2C and (1)F2E on both sides as shown. 2-Glue F2B and F2D as shown.
  • Page 23 STEP19 1-Glue F4B as shown. 2-Glue (4) F4C on front and rear, each sides of F4B F4C (X4) STEP20 1-Glue F5BB, FF6B, F7B,F8B and F9B as shown.
  • Page 24 STEP21 1-Glue (2) F16 as shown. STEP22 1-Glue F16A outside F16 as shown. 2-Glue F17 as shown. F16A...
  • Page 25 STEP23 1-Cut (2) 1/4 X 1/2 hardwood sticks. They should fit between both F16A 2-Glue (2) 1/4 X 1/2 hardwood sticks as shown. ¼ x ½ hardwood sticks F16A F16A STEP24 F15L 1-Glue F15 as shown on both sides. F15R F15L F15L and F15R not flush with FSL and FSR...
  • Page 26 STEP25 1-Glue (2) F14 as shown. F14 should be flush with tabs on top of F5B. STEP26 1-Glue (2) 1/4sq balsa stick as shown. They must locate on F15 1/4sq sticks 2-Trim flush with F9B. 1/4sq balsa sticks Fill with scrap balsa if required...
  • Page 27 STEP27 1-Cut (1) 1/4 x 1/2 hardwood stick and glue as shown. 2-Glue F28, F29 and F30 both sides as shown. 1/4 X 1/2 hardwood stick STEP28 1-Cut (2) 3/8 x 1/2 hardwood stick as shown. 2-Glue rear stick flush with F14 slot top. Flush 3-Glue front stick in F30 slots.
  • Page 28 STEP29 1-Cut (1) 1/8 x 1/2 balsa strip and glue as shown. 2-Sand strip to follow airfoil shape. Use top window as a gauge to keep step on the back. (do not sand with window installed to avoid damaging the window surface) Step equal to top 1/8 X 1/2 balsa strip window thickness...
  • Page 29 STEP31a 1-Cut (1) servo wiring tube 15 inches long. 2-Glue the tube flush with F9B and apply glue in holes of F6B to F8B Servo wiring tube Flush with F9B Servo wiring tube...
  • Page 30 STEP31b 1-Install (4) 6-32 T-nuts inside the fuselage 2-Install fuselage front brackets as shown using (4) 6-32 SHCS 5/8 long and (4) #6 washer as shown. Use (2) 6/32 locknuts inside the fuselage to secure screws as shown 3-Install tail flying wire bracket as shown using (2) 4-40 SHCS 1/2 long and (2) #4 as shown Fuselage strut bracket 4-40SHCS (2) 6-32SHCS (2)
  • Page 31 FUSELAGE ASSY PICTURES 1-Add scrap balsa to support covering properly as shown ¼ sq balsa in front of F9B Scrap balsa at rear of F5Band between F15 and F16...
  • Page 32 FUSELAGE ASSY PICTURES 1-Add scrap balsa to support covering properly as shown Add a piece of scrap balsa around bracket Add a piece of scrap balsa in front of stab Sand RF2 as shown...
  • Page 33 FUSELAGE ASSY PICTURES 1-Sand RF2 as shown. 2-Glue a piece of 1/8 balsa over F9B to match RF2 and allow proper covering installation...
  • Page 34 FUSELAGE ASSY PICTURES 1-Glue (2) scrap pieces of ½ x 1 ¼ leading edge stock and shape as shown 2-Sand blocks to fuselage shape once the front fuselage sheeting is installed as shown...
  • Page 35 STEP32a 1-Cut (1) 3/8sq hardwood stick 12.625 long. 2-Glue fin frame using R1A, R1B, R1C, R1F, R1G and R1H 3-Cut (2) pieces of 3/8 sq balsa to make ribs 4-Glue 3/8sq hardwood stick to trailing edge of rudder fin assembly 5-Trim top of hardwood flush with top of fin 6-Trim bottom of hardwood flush with bottom of fuselage tail 7-Drill (1) hole 1/8dia at location shown...
  • Page 36 STEP32b 1-Glue R2A and R2B to R2C as shown. 2-Glue R2D to complete the rudder. 3-Cut a 3/8sq balsa stick 15 inches long 4-Glue a 3/8 sq balsa stick and trim both end 5-Round trailing edge and bevel 45 degrees on each side of leading edge 5/8 DIA DOWEL Bevel leading edge 3/8 BALSA TRAILING EDGE...
  • Page 37 STEP32c 1-Mark lines as shown on both fin and rudder for Robart hinges (6 required) 7-Drill 3/16 dia holes using Robart drill jig on both fin and rudder 3/8’’ 2’’ (5 places)
  • Page 38 STEP32d 1-Glue (2) R1D on each side of rudder fin assembly as shown 2-Glue F21 as shown...
  • Page 39 STEP33 1-Glue rudder fin assembly as shown. 2-Measure assembly angle for perfect 90 degrees. between horizontal plane and rudder fin. 3-Glue F20 as shown. 4-Cut (4) ¼ X ½ X 1 15/16 long hardwood sticks. 5-Glue hardwood sticks in slots found in F20 and F21. They will be used to support elevator servos.
  • Page 40 STEP34 1-F19L and F19R are kept in place using No2 x ½ screws Use holes in F19L and F19R as guide to drill holes in rudder fin post and F26 parts located on each sides of F9B 5-Sand R1D flush to F19L and F19R F19L left side cover F19R right side cover...

  • Page 41: Elevator Servos Installation

    Elevator servos installation left side servo Right servo Elevator servos view from rear with F19L and F19R installed...
  • Page 42 STEP35 1-Glue F15A, F15B and F15C inside F15 on both sides of fuselage. Right side parts not shown for clarity. These parts will support the side windows. F15C F15A Left side F15B F15C Right side F15B...
  • Page 43 STEP36 1-Glue F25 over fuselage bottom as shown. 2-Cut (2) ¼ X ½ X 14 5/8 long hardwood sticks. ¼ X ½ hardwood sticks (2 required) 3-Glue the ¼ X ½ hardwood sticks between F3 and F5. 4-Install F27 rudder servo support and F28 fuel tank support using No2 X ½...

  • Page 44: Rudder Servo Installation

    Rudder servo installation 1-Glue F25 over fuselage bottom as shown. 2-Cut (2) ¼ X ½ X 14 5/8 long hardwood sticks. 3-Glue the ¼ X ½ hardwood sticks between F3 and F5. 4-Install F27 rudder servo support and F28 fuel tank support using No2 X ½...
  • Page 45 STEP37 1-Glue (5) 3/8 sq balsa stick between F1 and F2D. 2-Glue (6) F36 on each sides of fuselage. They locate in large slots in FS 3-Glue (1) F37 on each sides of fuselage as shown. Hole in F37 indicate the front. There are two locator design in F4 and F8 to align F37 properly 3/8 sq balsa sticks (5 required) F37 on both sides...
  • Page 46 STEP38a 1-Cut strips of 1/8 X 3/8 x36 inches long balsa sheeting. 1/8 X 3/8 balsa strip flush with FB 2-Glue pieces of balsa strips as indicated by arrows. Balsa strips should be flush wit FB 1/8 X 3/8 balsa strip 3/8sq balsa stick Sand 3/8sq balsa stick flush with 1/8 X 3/8 balsa strip...
  • Page 47 STEP38b 1-Cut strips of 1/8 X 3/8 x36 inches long balsa sheeting. 2-Glue pieces of balsa strips as indicated by arrows on right side as shown. 3-Glue (2) F12 as shown 4-using #4 X ½ long screws, install F19L and F19R. F19L (F19R on right side) F12 both sides...
  • Page 48 STEP39 1-Install tail wheel as shown using screw provided with tail wheel 2-Install Landing gear using (6) 8-32 SHCS and (6) #8 washers Use Locktite to secure main landing gear once the plane is finish 8-32 SHCS and #8 washers (6 places)
  • Page 49 STEP40 1-Glue wing tube and trim flush to F14 Glue wing tube and trim flush to F14...

  • Page 50: Stab And Elevator Assembly

    STAB AND ELEVATOR ASSEMBLY Follow directions carefully Always dry fit first Assemble all components on a flat building board...
  • Page 51 STAB ASSEMBLY STEP1 1-Glue E1 and E2 as shown. 2-Cut a 3/8sq hardwood stick 23 inches long 4-Glue a 3/8 sq hardwood stick and trim both end 5-Round leading edge. 6-Align with the fin and mark location of Robart hinges (5 required) 7-Drill 3/16 dia holes using Robart drill jig on both fin and rudder Round leading edge 1/8 dia holes...
  • Page 52 ELEVATOR ASSEMBLY STEP2 1-Glue E1 and E2 as shown. 2-Cut a 3/8sq hardwood stick 23 inches long 3-Glue a 3/8 sq hardwood stick and trim both end 4-Round leading edge. 5-Drill 2 holes 1/8 dia located at ¾ inch from end of hardwood stick 5/8DIA HARDWOOD DOWEL Bevel leading edge Round trailing edge...
  • Page 53 STAB AND ELEVATOR ASSEMBLY STEP3 1-Mark lines on both stab and elevators to align Robart hinges as shown. 2-Drill 3/16 dia holes using Robart drill jig on both fin and rudder 3 7/16 3 7/16...
  • Page 54 STAB INSTALLATION Follow directions carefully Always dry fit first Assemble all components on a flat building board...
  • Page 55 STAB INSTALLATION STEP1 1-Slide stab into slot found in rudder fin 2-Slightly lift on side of the stab to insert glue under on both side 3-Align carefully in both planes and secure while glue is bonding STAB ASSY Slide stab in slot 90 degrees Plane 1 90 degrees...

  • Page 56: Wing Assembly

    WING ASSEMBLY LEFT WING SHOWN IN INSTRUCTION INVERT FOR RIGHT WING Follow directions carefully Always dry fit first Assemble all components on a flat building board...
  • Page 57 WING ASSEMBLY STEP1 1-Assemble wing jig on a flat building surface 2-Assemble (3) set of WJ4 and WJ5 with WJ5 on the left 3-Assemble (1) Assembly of WJ4 and WJ5 with WJ5 on the right 4-Install WJ1 and WJ3 as shown 5-Slide WJ2 in the center slots as shown 6-Align jig with a straight edge And fix it to table using crews on WJ4...
  • Page 58 WING ASSEMBLY STEP2 1-Glue W5A and W5B on the outside of W5 rib as shown 2-Glue W6A and W6B on the inside of W6 rib as shown 3-Glue W19 and 20 between W5 and W6. Small hole in W22 and W23 indicate top and near W5 4-Glue W22 to W19 and W23 to W20 as shown 5-Install small bracket using 4-40 SHCS (X4), #4 washer (X8) and 4-40 locknuts (X4) 4-40 SHCS 5/8 long (X2)
  • Page 59 WING ASSEMBLY STEP3 1-Glue W8A and W8B on the outside of W8 rib as shown 2-Glue W9A and W9B on the inside of W9 rib as shown 3-Glue (2) W17 together. Align holes carefully 4-Glue W18 (X1) and W17 (X2) between W8 and W9. Small hole in W17 and W18 indicate top and near W8 5-Glue W36 in front of W17 and W37 on rear of W17 6-Glue W38 in front of W18 and W39 on rear of W18 7-Install large bracket using 4-40 SHCS (X4), #4 washer (X8) and 4-40 locknuts (X4)
  • Page 60 WING ASSEMBLY STEP4 1-Cut (4) ½ x ¼ hardwood stick to 44 inches long 2-Locate (1) ¼ x ½ bottom main spar on slot found on WJ5 2-Glue ribs W1 up to W12 over bottom main spar as shown 2-Glue W9A and W9B on the inside of W9 rib as shown Locate bottom main spar on slot W8-W9 assembly...
  • Page 61 WING ASSEMBLY STEP5 1-Glue top main spar over ribs 2-Glue W15 on front of ribs as shown. Notice small hole in W15 indicate top and near W1 Samll hole indicate top and near W1 Top main spar LEFT WING SHOWN...
  • Page 62 WING ASSEMBLY STEP6 1-Glue W14 on rear of ribs as shown. Notice small hole in W14 indicate top and near W7 2-Trim main top spar to allow W13 to be slided in the assembly 3-Insert and glue W13 as shown Small hole indicate top and near W1 LEFT WING SHOWN...
  • Page 63 WING ASSEMBLY STEP7 1-Glue 1/4sq balsa rear spar on top and bottom of wing as shown. It must be glued all along W14. Top rear spar Bottom rear spar LEFT WING SHOWN...
  • Page 64 WING ASSEMBLY STEP8 1-Glue wing servo wire tube between W1 and W9 2-Trim as shown Tube flush to W1 Wing servo wire tube Tube trimmed ¼’’ from to W9 LEFT WING SHOWN...
  • Page 65 WING ASSEMBLY STEP9 1-Glue (2) W21 webbing in front and rear of main spar between W1 and W2. Small hole in W21 indicate top and near W1 2-Glue (1) W30 webbing in front of rear spar between W1 and W2 3-Glue (3) W31 as shown.
  • Page 66 WING ASSEMBLY STEP10 1-Cut wing tube 14 ¼ inches long 2-Insert tube and apply glue to all ribs and webbing where the tube is . Tube should ptotrude approximatively 1/16 from W5 rib 3-Trim tube flush to W1 rib Apply glue to all ribs Apply glue along all webbings top and bottom Wing tube...
  • Page 67 WING ASSEMBLY STEP11 1-Glue W27 on outside of W5 2-Glue W28 on W27 WING ASSEMBLY STEP12a 1-Remove wing from jig 2-Trim main spars flush with W1 and W13 LEFT WING SHOWN...
  • Page 68 WING ASSEMBLY STEP12b 1-Glue (1) W29 webbing between W6 and W7 and (1) W29 between W9 and W10 2-Glue (1) W31 webbing between W6 and W7 LEFT WING SHOWN...
  • Page 69 WING ASSEMBLY STEP13 1-Install (1) ¼-20 T-Nut and apply glue to keep in place 2-Glue W25 to W1 as shown 3-Glue W26 to W1 as shown 4-Cut 3/8dia dowel to 1 inch length 5-Glue 3/8dia dowel into W26 3/8dia dowel WING ASSEMBLY STEP14a 1-Glue W16 as shown LEFT WING SHOWN...
  • Page 70 WING ASSEMBLY STEP14b 1-Using aileron hinge location ruler, mark lines on W14 edge 2-Using ¼ scrap balsa, build block ¾’’ wide as shown minimum 1/2 ‘’ thick 3-Glue block center with marked lines on W14 Ruler alignment marks Aileron hinge location ruler Mark lines Angle located Mark lines...
  • Page 71 WING ASSEMBLY STEP15 1-Using 1/8X4 balsa sheet, Apply sheeting to top of wing first as shown Full sheeting between W1 and W4 and between W12 and W13 Leading edge sheeting over main spar but leave 1/8 for best cap strip support as shown Trailing edge sheeting is 1,5 inch wide Sand leading edge sheeting flush to W15 and trailing edge sheeting flush to W14 and to ribs end 1/8 clearance for cap strips...
  • Page 72 WING ASSEMBLY STEP16a 1-Using 1/8X4 balsa sheet, Apply sheeting to bottom of wing as shown Full sheeting between W1 and W4 and between W12 and W13. Make opening for strut brackets (6 required) Leading edge sheeting over main spar but leave 1/8 for best cap strip support as shown Trailing edge sheeting is 1,5 inch wide except between W7 and W9 where it must cover aileron servo mounting plate Sand leading edge sheeting flush to W15 and trailing edge sheeting flush to W14 and to ribs end Make openings for strut brackets...
  • Page 73 WING ASSEMBLY STEP16b Aileron servo opening must clear area where servo is to be located for better servo installation Make openings to clear servo mounting tabs LEFT WING SHOWN...
  • Page 74 WING ASSEMBLY STEP17 1-Using 1/8X1/2 balsa strips, make cap strips for top and bottom as shown LEFT WING SHOWN...
  • Page 75 WING ASSEMBLY STEP18 1-Glue ½ 1 ¼ balsa leading edge 2-Glue 3/8sq balsa trailing edge 3-Shape leading edge using W1 and W13 build in leading edge profile 4-Shape Trailing edge as shown Trailing edge Leading edge Leading edge shape LEFT WING SHOWN...
  • Page 76 WING ASSEMBLY STEP19 1-Once the wing are covered, glue W33 wing tip support 2-Glue wing tip over W33 LEFT WING SHOWN...
  • Page 77 WING ASSEMBLY STEP20a 1-Locate WA1 over a flat building surface 2-Glue (7) WA2, (9) WA3 and 1 WA4 as shown 3-Sand WA1 flus to front of ribs and to top of ribs at trailing edge Sand trailing edge flush with ribs Sand trailing edge flush to front of ribs LEFT WING SHOWN...
  • Page 78 WING ASSEMBLY STEP20b 1-WA5 aileron leading edge 2-Sand WA5 bottom edge flush with bottom of WA1 Sand bottom edge flush to WA1 LEFT WING SHOWN...
  • Page 79 WING ASSEMBLY STEP21 1-Cut (2) strips of 1/8 balsa 21 inches long 2-Glue strips as shown 3-Trim flush with both sides of aileron 4-Glue atrailing edge made from 3/8sq balsa stick Front strip Rear strip Aileron trailing edge made of 3/8 sq balsa stick LEFT WING SHOWN...
  • Page 80 WING ASSEMBLY STEP22 1-Use 1/8X1/2 balsa strips to make cap strips as shown (7 required) 1/8 radius 2-Round leading edge as shown 3-Cut a 3/8X1/2 hardwood block ½ inch long 4-Glue the hardwood block into slot found on WA4 5-Drill hole for aileron horn screw Cap strip 1/2 radius Hardwood block...
  • Page 81 WING ASSEMBLY STEP23 Aileron hinge drill jig assembly: 1-Glue WADJ1 on each side of WADJ2 as shown 2-Drill a 3/16 dia hole in the center of WADJ2 using a press drill WADJ2 WADJ1 Locate drill jig on press drill table and align drill on V notch...
  • Page 82 WING ASSEMBLY STEP24 1-Using Aileron hinge location ruler, mark line on aileron leading edge as shown Notice the angle cut on the ruler should be near W7 end of aileron Ruler alignment marks 2-Drill (5) 3/16 dia holes as shown. Aileron hinge location ruler Angle near W7...
  • Page 83 WING ASSEMBLY STEP25 Aileron hinge drill jig assembly: 1-Glue WDJ1 on each side of WDJ2 as shown 2-Drill a 3/16 dia hole in the center of WDJ2 using a press drill WADJ2 WADJ1 Locate drill jig on press drill table and align drill on V notch...
  • Page 84 WING ASSEMBLY STEP26 1-Using aileron hinge location ruler, mark lines on wing sheeting 2-Using WDJ1 wing drill jig, ailgn on marked lines and drill (5) 3/16 dia holes Ruler alignment marks Aileron hinge location ruler Angle located On W7 Mark lines Marked lines Drill jig location LEFT WING SHOWN...

  • Page 85: Door Assembly

    DOOR ASSEMBLY Follow directions carefully Always dry fit first Assemble all components on a flat building board...
  • Page 86 DOOR ASSEMBLY STEP1 1-Install D1 on a falt building surface 2-Adjust D5 and D8 to remove interference 3-AdjustD6 and D7 to remove interference 4-Glue on D1 parts D5, D6, D7 and D8 5-Glue balsa filler as shown and sand flush Adjust D6 and D7 here Adjust D5 and D8 here Balsa filler...
  • Page 87 DOOR ASSEMBLY STEP2 1-Glue on D3 over D4as shown 2-Glue D3 and d4 assembly over STEP1 assembly 3-Glue D2 on assembly 4-Once plane is covered, glue window in frame. Drill jig location LEFT WING SHOWN...
  • Page 88 DOOR ASSY PICTURES...
  • Page 89 DOOR ASSY Add balsa blocks between lower door panels to support hinges Hinge holes located in fuselage front door frame. Add 3/8sq balsa sticks around door frame...

  • Page 90: Cowling Installation

    COWLING INSTALLATION The following pictures explain the installation of the cowling. 35% Decathlon Pictures shown are from the but the method is similar. Builder may choose different method for cowling installation .
  • Page 91 TOP COWLING PREPARATION Prepare top cowling as follow: There are two methods for trimming the top cowling. The easy one and the more scale like method 1-Easy method: Measure engine hub diameter and cut the front face of the cowling to clear the hub 1/8 all around. Install engine to verify proper clearance.
  • Page 92 BOTTOM COWLING PREPARATION-1 Prepare bottom cowling as follow: 1-Open up the rectangular cooler hole located under the light. You can choose to open the light as well depending what you want to do with it. 2-Measure engine exhaust pipes locations and open up the cowling. It is much safer to enlarge the holes slowly to avoid enlarging the holes too much.
  • Page 93 BOTTOM COWLING PREPARATION-2 Prepare bottom cowling as follow: Scale like method: 1-Align the part removed from the top cowling part on the lower cowling part. Use masking tape to keep it at the proper location. You will need fiber glass cloth and laminating epoxy for the next step. 2-Apply epoxy glue inside the cowling to cover the added part and the area of the bottom cowling adjacent to it.
  • Page 94 BOTTOM COWLING PREPARATION-3 Now it is required to reinforce the cowling flange with a piece of 1/4 X 1/2 hardwood stick 1-prepare (2) piece of 1/4 X 1/2 hardwood stick 8 1/2’’ long. 2-Using laminating epoxy, glue the sticks INSIDE the cowling fiberglass flange. This flange is made wider than necessary and will be trimmed after glue is dry.
  • Page 95 MATING TOP AND BOTTOM COWLING-1 2-Measure ¼’’ at front and rear end of the cowling. 1-Fit both parts together using masking tape. MAKE THE LINE OVER THE TOP COWLING AREA BOTTOM 3-Make a line between both marks and locate the 4-Mark other holes at 1 15/16’’...
  • Page 96 MATING TOP AND BOTTOM COWLING-3 5-Drill 7/64 diameter holes at locations marked. 6-Separate parts and enlarge holes in bottom cowling Drill through both parts part to 5/32 diameter BOTTOM BOTTOM 7-Install (10) 4-40 T-nuts on flange both sides and secure them with glue. 8-Reassemble both cowling halves using 4-40 X ½’’...
  • Page 97 MATING TOP AND BOTTOM COWLING-4 9-Make (2) blocks 1’’ long from ¼ X ½ hardwood 10-The wedge should fit as shown in this picture and and sand a wedge shape at 1 end to fit inside locate the bottom part properly. top cowling 11-Locate and glue the hardwood parts using laminating epoxy made thicker using sand dust...
  • Page 98 MATING TOP AND BOTTOM COWLING-5 15-Enlarge holes in top cowling blocks to 5/32’’ 16-Install (1) 4-40 T-nut in each holes diameter 17-Use (12) 4-40 button head cap screws ½’’ long to assemble both cowling parts together. 18-Use (8) 4-40 socket cap screws ¾’’ long and (1) ½’’...
  • Page 99 COWLING INSTALLATION-1 The method shown here is a suggestion. Assemble (8) cowling support brackets made from scrap ¼ liteply and ¼ balsa or use simple hardwood blocks 1-Glue ¼ liteply support made from scrap plywood as shown for each bracket assembly 2-Glue side plates on each assembly as shown 3-Using scrap ¼...
  • Page 100 COWLING INSTALLATION-3 1-Using #4 countersink screw X ¾ long screws, install cowling support blocks on F1 as shown. To make support block, scrap ¼ liteply and ¼ balsa 2-Locate the top center block. It will be glued in place later. For now, use small tack of glue to keep it in place. 3-Light sand the balsa block over each block to have the proper shape.
  • Page 101 COWLING INSTALLATION-4 1-Locate the top cowling part over the brackets and hold in place using masking tape. 2-Measure each side to make sure of proper alignment. Make marks to locate the top cowling. 3- If the fit between the dashboard and the top cowling is not perfect, lightly sand the balsa block until fit is good. Do not sand the 1/8 sheeting around front of fuselage.
  • Page 102 COWLING INSTALLATION-5 1-Apply masking tape around the front of the dashboard and mark location of the center of each top brackets. 2-Install the top cowling, apply tape on the edge of the cowling and transfer marks from dashboard locations to the cowling.
  • Page 103 COWLING INSTALLATION-6 1-Using a 7/64 diameter drill (2.78mm), make 5 holes at marked locations. Drill through both the cowling and the support brackets 2-Using a 5/32 diameter drill (3,97mm), enlarge holes made in support brackets only 3-Install (1) 4-40 T-nut inside each assembly and glue it in place. 4-Untack the top center bracket, install 4-40 T-nut and glue bracket in place with carpenter glue or epoxy.
  • Page 104 COWLING INSTALLATION-7 Use (8) 4-40 socket cap screw ¾’’ long and (1) ½’’ long (top center bolt) to secure the cowling to the fuselage as shown. If required, sand the fuselage 1/8 balsa sheeting to match the cowling properly.
  • Page 105 COWLING INSTALLATION-8 1-Install (2) fairing made from scrap 1/8 plywood as shown in picture below Notice the cutout made on the cowling to increase air exit...
  • Page 106 STRUTS INSTALLATION-1 You will need to make 2 sets of struts (left and right wing struts assemblies) Front and rear strut need to be prepared as follow: 1-Using a band saw, cut in FRONT strut a slot 2 inches long at one end 3/32 wide approximatively 2-Using a band saw, cut in REAR strut a slot 1 1/8 inches long at one end 3/32 wide approximatively 3-using band saw, remove excess material at L.E.
  • Page 107 STRUTS INSTALLATION-2 1-Using 4-40 x ¾ long SHCS, secure large bracket to FRONT strut. 4-40 X 3/4 SHCS (2) 4-40 locknut #4 washer 2-Mark location of holes in the REAR strut using the small aluminium bracket as hole location jig. Bracket should be flush with leading edge of REAR strut.
  • Page 108 STRUTS INSTALLATION-2a 1-Using 4-40 x 5/8 long SHCS, secure large bracket to REAR strut. 4-40 X 5/8 SHCS (2) 4-40 locknut #4 washer 2-Trim FRONT strut at a length of 28 5/8’’ 3-Trim REAR strut at a length of 28 1/8’’ 4-Cut end of FRONT strut as shown to fit between front wing brackets 5-Cut end of REAR strut as shown to fit between rear wing brackets 7/8’’...
  • Page 109 STRUTS INSTALLATION-2b Front strut end shape Rear strut end shape Round end of strut as shown Round end of strut as shown...
  • Page 110 STRUTS INSTALLATION-3 1-Drill 1/8 dia hole in the end of the FRONT strut as shown 2-Drill 1/8 dia hole in the center of REAR strut as shown FRONT strut REAR strut end 1/4’’ 1/4’’...
  • Page 111 STRUTS INSTALLATION-4 1-Using .020 aluminium sheet, cut (1) strap 4 ¼ inches long and ½ inch wide. Round each end 2-Wrap the strap over the end of the FRONT strut 3-Drill 2 holes through the strap and the FRONT strut. First hole at ¾’’ from end second hole at ½’’ from first hole 4-Use 4-40 SHCS 1’’...
  • Page 112 STRUTS INSTALLATION-5 1-Using .020 aluminium sheet, cut (1) strap using the template provided below. Use the tmplate provided to make the bracket. 2-Wrap the strap over the end of the REAR strut 3-Drill 2 holes through the strap and the REAR strut. First hole at ¾’’ from end second hole at ½’’ from first hole 4-Use 4-40 SHCS ¾’’...
  • Page 113 STRUTS INSTALLATION-6 1-Drill 1/8 dia hole at 16 ½’’ from the end near the fuselage on the FRONT strut as shown in picture. Interstruts must be perpendicular to wing bottom so the hole must be made to suit this requirement Measure from here Center of strut Leading...
  • Page 114 STRUTS INSTALLATION-7 1-Make (2) interstrut brackets from .020 aluminium as per sketch shown below for each wings 2-Bend each bracket 65 degrees up in the center of bracket 65 deg...
  • Page 115 STRUTS INSTALLATION-8 1-Install both wings on fuselage using the 1 ¼’’ dia aluminium tube and (2) ¼-20 nylon bolts 2-Assemble rear strut to front strut using (1) 4-40 SHCS 3/8’’ long with (1) 4-40 locknut and (3) #4 washers 3-Install strut assembly to the airframe using 6-32 SHCS ½’’ long with (1) 6-32 locknut and (2) #6 washers on each sides 4-Attach end of struts to the wing using (2) 4-40 SHCS 1’’...
  • Page 116 STRUTS INSTALLATION-9 1-Install interstrut bracket on front and rear struts as shown 2-Using 3/16’’ dia tube make (2) of each interstrut tubes as per the following dimensions: NOTE: prior drilling tube ends, use a hammer or a vise to make ends flat 3-Use (1) 4-40 SHCS 1’’...
  • Page 117 STRUTS INSTALLATION-10a 1-Install interstrut tubes as shown. Use (4) 4-40 SHCS 3/8’’ long with (4) 4-40 locknuts and (8) #4 washers on each wings Wing Interstrut bracket Wing Interstrut Front Interstrut Rear Interstrut bracket Inter tube...
  • Page 118 STRUTS INSTALLATION-10b Front view of interstruts installation...

  • Page 119: Windshield Installation

    WINDSHIELD INSTALLATION-1 1-Prior gluing the front windshield, dry fit over the fuselage. Use tape to hold in place 2-Secure the top of window using (5) #4X ½ screws on the hardwood stick located in front of F2B. Make sure it align perfectly with F14 outer wall...
  • Page 120 WINDSHIELD INSTALLATION-2 1-you can apply light heat using an hair dryer to pre-form the windshield. Do not apply too much heat since it may distort the windshield. 2-Once fit is good, start gluing the front center portion using Pacer Formula560 canopy glue or equivalent glue.
  • Page 121 WINDSHIELD INSTALLATION-3 1-Once the windshield is secure, use ½ automotive trim tape to finish the contour of the windshield 2-Install top rear window using (14) #4 X ½ screws as shown in picture...
  • Page 122 WINDSHIELD INSTALLATION-4 1-there are (2) front side windows. One of them is a bit smaller. This is the one that is going in the door aperture. The other one is installed in the fuselage left side. 2-Glue both front window in their proper location using Formula560 glue or equivalent. 3- Glue both rear window on each sides of the fuselage.

  • Page 123: Flying Wires Installation

    FLYING WIRES INSTALLATION-1 1-there are (8) flying wire brackets (sullivan tabs) and one larger braket that is located under the rear end of the fuselage. rear flying wire bracket Sullivan tabs used as flying wire brackets...
  • Page 124 FLYING WIRES INSTALLATION-2 1-Install both stabs on the plane 2-Measure distance from tip of stab to tip of rudder fin. This measure should be equal on both sides. Maintain perpendicularity between surfaces using tape. 3-Bend sullivan tabs as shown in order to have straight line between both ends of wire. 4-Use (3) 4-40 X ¾...
  • Page 125 FLYING WIRES INSTALLATION-3 Pictures below indicates the way that flying wires are installed. Do not adjust them so that they are too tight. They should be straight but not too tight.

  • Page 126: Wing Tip Installation

    WING TIP INSTALLATION-1 1-Paint the wing tip first. Wing tip will be glued over wing tip support 2-Prior gluing anything, dry fit the W33 rib inside each wing tip. It is required to sand the trailing edge taper to fit the wing tip Carefully locate W33 over W13.
  • Page 127 WING TIP INSTALLATION-2 4-Now, slide the fiberglass wing tip over W33 and check fit between wing tip and wing profile. You may have to add shim to W33 or to sand either the wing tip inner area or W33 outer profile a little bit so that wing tip fit perfectly. To sand W33, it is better to remove it from wing assembly...
  • Page 128 WING TIP INSTALLATION-3 5-When the wing tip match the wing profile properly, apply glue to W33 and glue it in place. 6-Last step is to glue the wing tip or use small screws all around if you want it removable. (screws not provided in kit)
  • Page 129 SERVOS INSTALLATION-1 1-Aileron: Notice: SHCS bolts required to connect to servos are not includes in kit A-Drill and tap 1 hole for 8-32 screw in hardwood aileron block (approximatively ¾ inch deep) B-Install horn and locknut on 8-32 screw. Screw them until they reach the head of the screw C-Apply glue in hole and install 8-32.
  • Page 130 SERVOS INSTALLATION-2 1-Elevator: Notice: SHCS bolts required to connect to servos are not includes in kit A-Use 2 inches 8-32 SHCS and plastic washer and install it in 3/16 dia hole found in the elevator B-Install lock nut and horn on the other side to proper position C-Make the required linkage as shown on pictures.
  • Page 131 SERVOS INSTALLATION-3 1-Rudder: Notice: Pull-Pull cable is not included in kit. SHCS bolts required to connect to servos are not includes in kit A-Use (1) 3 inches 8-32 threaded rod and (2) locknuts and install it in 3/16 dia hole found in the rudder B-Install (2) horns on the each sides to proper position C-Make the required pull-pull cables as shown on pictures.
  • Page 132 SERVOS INSTALLATION-4 1-Engine: Notice: SHCS bolts required to connect to servos are not includes in kit Throttle and choke servos can be installed inside the fuselage but there will be no easy access in case of problem with these servos once the plane is completed. Depending on the engine used, servos installation may differ significantly.

  • Page 133: Tank Installation

    TANK INSTALLATION Tank should be installed on the plate and approximatively centered on the CG We usually suggest to use velcro under the tank and a tie wrap to secure it to mounting plate.
  • Page 134 Recommended engines: DLE30 up to DLE55, DA50, MOKI 45, NGH GT35, PTERODACTYL 36, RCGF32 to 45 single or 40 or 50 TWIN, ROTO35, ZDZ40 to 50 all available from AMR-RC. It is strongly recommended to stay within this range. Failure to do this may damage the...

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