Horizon Hobby HANGAR 9 Assembly Manual
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Horizon Hobby HANGAR 9 Assembly Manual

Model aircraft horizon hobby hangar 9
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Specifications
Wingspan. . ....................................80.5.in.(2045mm)
Wing.Area...........................933.sq.in.(60.19.sq.dm)
Length. . .........................................60.6.in.(1539mm)
Sundowner
Assembly mAnuAl
Weight. . ............................12–14.lb.(5.44kg–6.35kg)
Engine. . ................................. . 1 .20–1.80.Four-Stroke
....................................................26–35cc.Gasoline
Motor............................................. E-flite.Power.160

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Summary of Contents for Horizon Hobby HANGAR 9

  • Page 1 Sundowner Assembly mAnuAl Specifications Wingspan........80.5.in.(2045mm) Weight......12–14.lb.(5.44kg–6.35kg) Wing.Area......933.sq.in.(60.19.sq.dm) Engine........1 .20–1.80.Four-Stroke Length...........60.6.in.(1539mm) ............26–35cc.Gasoline Motor..........E-flite.Power.160...

  • Page 2: Table Of Contents

    Table of Contents Using.the.Manual..............3 Required.Tools.and.Adhesives.

  • Page 3: Using.the.manual

    Using the Manual This.manual.is.divided.into.sections.to.help.make.assembly.easier.to.understand,.and.to.provide.breaks.between.each. major.section..In.addition,.check.boxes.have.been.placed.next.to.each.step.to.keep.track.of.each.step.completed..Steps.    with.a.single.box.( ).are.performed.once,.while.steps.with.two.boxes.( ).indicate.that.the.step.will.require. repeating,.such.as.for.a.right.or.left.wing.panel,.two.servos,.etc..Remember.to.take.your.time.and.follow.the.directions. Required Tools and Adhesives Tools •.Rotary.tool.(dremel). •.Sanding.drum.1/4-inch •.Pliers. •.T-pins •.Solder. . •.Solder.gun •.File. •.4/40.tap •.Hex.wrench:.3/32-inch•.Square. •.Hobby.knife •.Phillips.screwdriver. •.Adjustable.wrench •.Drill. •.Felt-tipped.pen •.Ruler •.. D rill.bit:.1/16-inch.(1.5mm),.5/64-inch.(2mm),.3/32-inch.or.#.43.bit.(2.5mm),.7/64".bit.(3mm),.5/32-inch.(4mm),. 11/64-inch.(4.5mm) Adhesives •.Thin.CA.(PAAPT08). •.30-minute.Epoxy.(HAN8002) •.CA.Remover/Debonder.(PAAPT16).

  • Page 4: Radio.and.power.systems.requirements

    Radio and Power Systems Requirements •.4-channel.radio.system.(minimum).w/receiver. •.ST125MG.Servo.(JSP20070).(5).or.equivalent •.6-inch.Servo.Lead.Extension.(JRPA095).(3). •.9-inch.Servo.Lead.Extension.(JRPA097).(2) •.18-inch.Servo.Lead.Extension.(JRPA099).(3) Recommended JR ® or JR SPORT ™ Systems •.XP9303. . •.XP7202 •.DX7. •.XP6102 •.XS600 E-Flite Power 160 EFLM4160A Recommended Setup–Gas/Glow •.Evolution.26GT2.Gas.Engine.(EVOE26GT2),.OR •.Saito.180.AAC.with.Muffler.(SAIE180.or.SAIE180GK) Saito 1.80 Golden Knight AAC SAIE180GK •.Muffler.Right.Angle.Adapter.(Saito.only).(SAI120S140) •.14x12.–.16x8.Propeller •.3 -inch.TruTurn.Spinner.(TRU3252) Evolution 26GT2...

  • Page 5: Warranty.period

    Warranty Period Exclusive.Warranty-.Horizon.Hobby,.Inc.,.(Horizon).warranties.that.the.Products.purchased.(the."Product").will.be.free. from.defects.in.materials.and.workmanship.at.the.date.of.purchase.by.the.Purchaser. Limited Warranty (a).This.warranty.is.limited.to.the.original.Purchaser.("Purchaser").and.is.not.transferable..REPAIR.OR.REPLACEMENT. AS.PROVIDED.UNDER.THIS.WARRANTY.IS.THE.EXCLUSIVE.REMEDY.OF.THE.PURCHASER..This.warranty.covers.only. those.Products.purchased.from.an.authorized.Horizon.dealer..Third.party.transactions.are.not.covered.by.this.warranty.. Proof.of.purchase.is.required.for.warranty.claims..Further,.Horizon.reserves.the.right.to.change.or.modify.this.warranty. without.notice.and.disclaims.all.other.warranties,.express.or.implied.. (b).Limitations-.HORIZON.MAKES.NO.WARRANTY.OR.REPRESENTATION,.EXPRESS.OR.IMPLIED,.ABOUT.NON- INFRINGEMENT,.MERCHANTABILITY.OR.FITNESS.FOR.A.PARTICULAR.PURPOSE.OF.THE.PRODUCT..THE.. PURCHASER.ACKNOWLEDGES.THAT.THEY.ALONE.HAVE.DETERMINED.THAT.THE.PRODUCT.WILL.SUITABLY.MEET. THE.REQUIREMENTS.OF.THE.PURCHASER’S.INTENDED.USE.. (c).Purchaser.Remedy-.Horizon's.sole.obligation.hereunder.shall.be.that.Horizon.will,.at.its.option,.(i).repair.or.(ii). replace,.any.Product.determined.by.Horizon.to.be.defective..In.the.event.of.a.defect,.these.are.the.Purchaser's.exclusive. remedies..Horizon.reserves.the.right.to.inspect.any.and.all.equipment.involved.in.a.warranty.claim..Repair.or.replacement. decisions.are.at.the.sole.discretion.of.Horizon..This.warranty.does.not.cover.cosmetic.damage.or.damage.due.to.acts.of. God,.accident,.misuse,.abuse,.negligence,.commercial.use,.or.modification.of.or.to.any.part.of.the.Product..This.warranty. does.not.cover.damage.due.to.improper.installation,.operation,.maintenance,.or.attempted.repair.by.anyone.other.than. Horizon..Return.of.any.goods.by.Purchaser.must.be.approved.in.writing.by.Horizon.before.shipment. Damage Limits HORIZON.SHALL.NOT.BE.LIABLE.FOR.SPECIAL,.INDIRECT.OR.CONSEQUENTIAL.DAMAGES,.LOSS.OF.PROFITS.OR. PRODUCTION.OR.COMMERCIAL.LOSS.IN.ANY.WAY.CONNECTED.WITH.THE.PRODUCT,.WHETHER.SUCH.CLAIM. IS.BASED.IN.CONTRACT,.WARRANTY,.NEGLIGENCE,.OR.STRICT.LIABILITY..Further,.in.no.event.shall.the.liability.of. Horizon.exceed.the.individual.price.of.the.Product.on.which.liability.is.asserted..As.Horizon.has.no.control.over.use,. setup,.final.assembly,.modification.or.misuse,.no.liability.shall.be.assumed.nor.accepted.for.any.resulting.damage.or. injury..By.the.act.of.use,.setup.or.assembly,.the.user.accepts.all.resulting.liability. If.you.as.the.Purchaser.or.user.are.not.prepared.to.accept.the.liability.associated.with.the.use.of.this.Product,.you.are. advised.to.return.this.Product.immediately.in.new.and.unused.condition.to.the.place.of.purchase. Law:.These.Terms.are.governed.by.Illinois.law.(without.regard.to.conflict.of.law.principals). Safety Precautions This.is.a.sophisticated.hobby.Product.and.not.a.toy..It.must.be.operated.with.caution.and.common.sense.and.requires. some.basic.mechanical.ability..Failure.to.operate.this.Product.in.a.safe.and.responsible.manner.could.result.in.injury.. or.damage.to.the.Product.or.other.property..This.Product.is.not.intended.for.use.by.children.without.direct.adult. supervision..The.Product.manual.contains.instructions.for.safety,.operation.and.maintenance..It.is.essential.to.read.. and.follow.all.the.instructions.and.warnings.in.the.manual,.prior.to.assembly,.setup.or.use,.in.order.to.operate.correctly. and.avoid.damage.or.injury.

  • Page 6: Questions,.Assistance,.And.repairs

    Questions, Assistance, and Repairs Your.local.hobby.store.and/or.place.of.purchase.cannot.provide.warranty.support.or.repair..Once.assembly,.setup.or. use.of.the.Product.has.been.started,.you.must.contact.Horizon.directly..This.will.enable.Horizon.to.better.answer.your. questions.and.service.you.in.the.event.that.you.may.need.any.assistance..For.questions.or.assistance,.please.direct.your. email.to.productsupport@horizonhobby.com,.or.call.877.504.0233.toll.free.to.speak.to.a.service.technician. Inspection or Repairs If.this.Product.needs.to.be.inspected.or.repaired,.please.call.for.a.Return.Merchandise.Authorization.(RMA)..Pack.. the.Product.securely.using.a.shipping.carton..Please.note.that.original.boxes.may.be.included,.but.are.not.designed.. to.withstand.the.rigors.of.shipping.without.additional.protection..Ship.via.a.carrier.that.provides.tracking.and.insurance. for.lost.or.damaged.parcels,.as.Horizon is not responsible for merchandise until it arrives and is accepted at our facility..A.Service.Repair.Request.is.available.at.www.horizonhobby.com.on.the.“Support”.tab..If.you.do.not.. have.internet.access,.please.include.a.letter.with.your.complete.name,.street.address,.email.address.and.phone.number. where.you.can.be.reached.during.business.days,.your.RMA.number,.a.list.of.the.included.items,.method.of.payment.. for.any.non-warranty.expenses.and.a.brief.summary.of.the.problem..Your.original.sales.receipt.must.also.be.included.. for.warranty.consideration..Be.sure.your.name,.address,.and.RMA.number.are.clearly.written.on.the.outside.of.the. shipping.carton. Warranty Inspection and Repairs To receive warranty service, you must include your original sales receipt.verifying.the.proof-of-purchase. date..Provided.warranty.conditions.have.been.met,.your.Product.will.be.repaired.or.replaced.free.of.charge..Repair.or.

  • Page 7: Safety,.Precautions,.And.warnings

    Safety, Precautions, and Warnings This.model.is.controlled.by.a.radio.signal.that.is.subject.to.interference.from.many.sources.outside.your.control..This. interference.can.cause.momentary.loss.of.control.so.it.is.advisable.to.always.keep.a.safe.distance.in.all.directions.around. your.model,.as.this.margin.will.help.to.avoid.collisions.or.injury. •.Always.operate.your.model.in.an.open.area.away.from.cars,.traffic,.or.people. •.Avoid.operating.your.model.in.the.street.where.injury.or.damage.can.occur. •.Never.operate.the.model.into.the.street.or.populated.areas.for.any.reason. •.Never.operate.your.model.with.low.transmitter.batteries. •.. C arefully.follow.the.directions.and.warnings.for.this.and.any.optional.support.equipment.(chargers,.rechargeable. battery.packs,.etc.).that.you.use. •.Keep.all.chemicals,.small.parts.and.anything.electrical.out.of.the.reach.of.children. •.. M oisture.causes.damage.to.electronics..Avoid.water.exposure.to.all.equipment.not.specifically.designed.and.protected. for.this.purpose. Contents of Kit Replacement Parts A.. HAN4501. Left.Wing.Panel.w/Aileron B.. HAN4502. Right.Wing.Panel.w/Aileron C.. HAN4503. Fuselage D.. HAN4504. Stabilizer.Set.w/Elevators E.. HAN4505. Rudder F..

  • Page 8: Landing.gear.installation

    Landing Gear Installation Required Parts  .Step 2 •.Fuselage. •.Landing.gear Secure.the.axles.to.the.landing.gear.using.the.provided. •.3 -inch.wheel.(2). •.#4.washer.(4) nuts.and.an.adjustable.wrench. •.2-inch.axles.w/lock.nuts. •.#8.washer.(8) •.4-40.x.1/2-inch.socket.head.screw.(4) •.8-32.x.3/4-inch.machine.screw.(4) •.3mm.x.4mm.machine.screw.(4) •.Wheel.pant.(left.and.right) •.5/32-inch.wheel.collar.(4) Required Tools and Adhesives •.Adjustable.wrench. •.Phillips.screwdriver •.Hex.wrench:.3/32-inch. •.Threadlock  .Step 3 •.Rotary.tool.w/sanding.drum.or.file Secure.the.landing.gear.to.the.bottom.of.the.fuselage. using.four.8-32.machine.screws,.four.lock.nuts.and.eight.  .Step 1 #8.washers..The.lock.nuts.will.be.inside.the.fuselage.as. Remove.the.two.4-40.socket.head.bolts.that.secure.the.
  • Page 9 Landing Gear Installation   .Step 4 .Step 6 Use.a.file.or.rotary.tool.to.grind.a.flat.area.on.the.. Attach.the.wheel.pant.to.the.landing.gear.using.two.. axle.where.the.screws.from.the.wheel.coller.will.be.. 4-40.x.1/2-inch.socket.head.screws.and.two.#4.washers. positioned.when.tightened.  .Step 7 Note:.Use.threadlock.on.all.metal- Loosen.the.3mm.x.4mm.machine.screws.in.the.wheel. to-metal.fasteners.to.prevent.them. collars..Position.the.wheel.so.it.is.centered.in.the.opening. from.vibrating.loose.in.flight. in.the.wheel.pant..Tighten.the.screws.to.secure.the.wheel. in.position.  .Step 5 Slide.a.5/32-inch.wheel.collar.onto.the.axle.then.the. wheel..A.second.wheel.collar.is.then.placed.on.the.axle.. Install.the.3mm.x.4mm.machine.screws.away.from.the. fuselage.so.they.can.be.accessed.later.

  • Page 10: Aileron.installation

    Aileron Installation Required Parts   .Step 2 •.Wing.(left.and.right). •.CA.hinge.(8) Tie.a.weight.to.a.string.and.lower.the.weight.into.the. •.Aileron.(left.and.right). •.8-32.flanged.nut.(2) opening.for.the.aileron.servo. •.2 pushrod.linkage •.Control.horn.connector.(2) •.Ball.link.end.w/hardware(2) •.8-32.x.2 -inch.countersunk.screw.(2) Required Tools and Adhesives •.Servo.(2). •.Thin.CA •.String. •.T-pins •.Rotary.tool •.Drill.bit:.1/16-inch.(1.5mm),.7/65-inch.(3mm) •.9-inch.(228mm).servo.extension.(2)   .Step 1 Remove.the.servo.horn.from.the.servo..Secure.a..   .Step 3 9-inch.(305mm).servo.extension.to.the.servo.lead.using.

  • Page 11: Aileron Installation

    Aileron Installation     .Step 4 .Step 6 Tie.the.string.to.the.servo.extension..Use.the.string.to.pull. Use.the.hardware.provided.with.the.servo.to.secure.it.in. the.servo.extension.through.the.wing. the.wing..The.output.shaft.of.the.servo.will.face.toward.the. aileron..After.installing.the.screws,.remove.them.and.soak. thin.CA.into.the.holes.to.harden.the.threads.   .Step 5 Thread.the.screws.to.mount.the.servo.into.the.holes,.then. remove.them..Apply.a.few.drops.of.thin.CA.into.the.holes. to.harden.the.threads.   .Step 7 Use.a.rotary.tool.and.1/16-inch.(1.5mm).drill.bit.to.. drill.a.hole.in.the.center.of.each.of.the.four.hinge.slots.. in.the.wing.
  • Page 12 Aileron Installation     .Step 8 .Step 10 Position.the.aileron.against.the.wing..Transfer.the.. Position.the.CA.hinges.in.the.aileron..The.slot.in.. location.of.the.holes.drilled.in.the.previous.step.to.the. the.hinge.will.align.with.the.hole.drilled.in.the.aileron.. aileron..Use.a.rotary.tool.and.1/16-inch.(1.5mm).drill.bit. in.Step.7. to.drill.holes.at.these.locations.   .Step 11 Note:.Steps.6.and.7.are.to.create.a. Slide.the.hinges.in.the.aileron.into.the.slots.in.the.wing.. tunnel.for.the.CA.to.wick.into.the.hinge.. Position.the.aileron.so.there.is.equal.distance.at.each.end. This.provides.the.best.bond.between. between.the.wing.and.aileron..Remove.the.T-pins.and. the.hinge.and.gluing.surfaces. push.the.aileron.tight.against.the.wing..Flex.the.aileron. and.apply.thin.CA.to.each.of.the.four.hinges..Make.sure.to.   .Step 9 apply.CA.to.both.the.top.and.bottom.of.each.hinge. Place.a.T-pin.in.the.center.of.four.of.the.CA.hinges. Note:.Do.not.use.CA.accelerator.on.the. hinges..The.CA.must.be.allowed.to.wick. fully.into.the.hinge.to.provide.the.best.bond. between.the.hinge.and.surrounding.wood.
  • Page 13 Aileron Installation     .Step 12 .Step 14 Once.the.CA.has.fully.cured.lightly.pull.on.the.wing.and. Slide.the.8-32.x.2 -inch.countersunk.screw.through.. aileron.to.make.sure.the.hinges.are.securely.glued.to.the. the.hole.in.the.aileron.from.the.top.of.the.wing..Secure.. wing.and.aileron. the.screw.using.an.8-32.flanged.nut..Use.threadlock.on. the.screw.and.nut.to.prevent.vibrations.from.loosening.. the.nut.   .Step 15   .Step 13 Assemble.the.aileron.linkage.using.the.2 -inch.. Flex.the.aileron.up.and.down.a.few.times.to.break.in.. control.rod,.ball.end.and.control.horn.connector.as. the.hinge. shown..The.length.of.the.linkage.will.be.approximately.. 4.inches.(102mm).
  • Page 14 Aileron Installation     .Step 16 .Step 18 Thread.the.control.horn.connector.onto.the.countersunk. Secure.the.servo.horn.to.the.servo.so.it.is.parallel.to.the. screw.so.the.distance.between.the.control.surface.and. aileron.hinge.line..Adjust.the.length.of.the.linkage.so.the. bottom.of.the.connector.is.5/8-inch.(16mm). aileron.is.in.the.neutral.position.    .Step 17 .Step 19 Drill.a.7/64-inch.(3mm).hole.through.the.control.horn. Repeat.Steps.1.through.18.for.the.remaining.wing.. that.is.1/2-inch.(13mm).from.the.center.ofthe.servo.arm.. and.aileron. Attach.the.ball.end.to.the.servo.horn.using.the.hardware. provided.with.the.kit.

  • Page 15: Rudder.installation

    Rudder Installation Required Parts  .Step 2 •.Fuselage. •.Rudder Use.four.CA.hinges.to.attach.the.rudder.to.the.fin.and. •.CA.hinge.(4). •.8-32.flanged.nut fuselage..Follow.the.same.procedure.as.described.in. hinging.the.ailerons. •.Tailwheel.assembly. •.Steering.bracket •.Metal.clevis. •.4-40.nut •.Control.horn.connector. •.1/4-inch.tubing •.Steering.spring.(2) •.5. -inch.(140mm).pushrod •.8-32.x.2 -inch.countersunk.screw •.#4.x.5/8-inch.sheet.metal.screw.(2) •.#2.x.1/2-inch.sheet.metal.screw.(2) Required Tools and Adhesives •.Drill •.Hex.wrench:.3/32-inch. •.T-pins •.Felt-tipped.pen. •.Pliers •.18-inch.(458mm).servo.extension  .Step 3 •.Drill.bit:.5/64-inch.(2mm) Install.the.8-32.x.2 -inch.countersunk.screw.and.secure.
  • Page 16 Rudder Installation   .Step 4 .Step 6 Position.the.tailwheel.assembly.onto.the.bottom.of.the. Attach.the.tailwheel.bracket.using.two.#4.x.5/8-inch.. fuselage..Make.sure.the.bracket.is.as.far.forward.as. sheet.metal.screws..After.installing.the.screws,.. possible.but.does.not.overlap.onto.the.servo.opening..Use. remove.them.and.soak.thin.CA.into.the.holes.to.. a.felt-tipped.pen.to.mark.the.locations.for.the.two.screws. harden.the.threads.   .Step 5 .Step 7 Drill.two.5/64-inch.holes.at.the.locations.marked.in.the. Position.the.steering.bracket.with.the.front.edge.roughly. previous.step. 3/4-inch.back.from.the.rudder.hinge.line..Attach.the. steering.bracket.to.the.bottom.of.the.rudder.using.two.. #2.x.1/2-inch.sheet.metal.screws..After.installing.the. screws,.remove.them.and.soak.thin.CA.into.the.holes.to. harden.the.threads.

  • Page 17: Rudder.installation

    Rudder Installation   .Step 8 .Step 10 Use.the.two.steering.springs.to.connect.the.steering. Thread.the.control.horn.connector.onto.the.countersunk. bracket.to.the.tailwheel.actuator..You.will.need.to.bend.the. screw.so.the.distance.between.the.control.surface.and. springs.at.each.end.using.pliers.to.make.the.connections. bottom.of.the.connector.is.13/16-inch.(20mm).  .Step 9  .Step 11 Attach.an.18-inch.(458mm).servo.extension.to.the.rudder. Assemble.and.install.the.linkage.for.the.rudder.servo. servo..Install.the.rudder.servo.into.the.fuselage.using.the. using.a.5. -inch.pushrod..The.end.attaching.to.the.. hardware.provided.with.the.servo..With.the.rudder.servo. servo.is.prepared.by.threading.a.4-40.nut.onto.the. centered.using.the.radio,.install.a.long.servo.horn.onto. linkage..Slide.a.1/4-inch.piece.of.tubing.onto.the.clevis. the.rudder.servo.positioned.so.it.is.perpendicular.to.the. and.thread.the.clevis.onto.the.linkage..Adjust.the.length.of. fuselage.center.line. the.linkage.to.approximately.6. -inch.(165mm)..Attach. the.clevis.to.the.control.horn.so.it.is.3/4-inch.(19mm). from.the.center.of.the.servo.arm. Note:.Once.the.linkage.has.been.adjusted.to. its.final.length,.tighten.the.4-40.nut.against. the.clevis.to.keep.them.from.vibrating.loose. and.changing.the.length.of.the.linkage. Important:.Use.threadlock.on.

  • Page 18: Stabilizer.installation

    Stabilizer Installation Required Parts  .Step 2 •.Fuselage. •.Stabilizer.tube.(long) Slide.the.longer.stabilizer.tube.into.the.rear.fiberglass.tube. •.Stabilizer.tube.(short). •.8-32.flanged.nut.(2) in.the.fuselage..Center.the.rod.in.the.fuselage. •.Stabilizer.(right.and.left). •.#4.washer.(2) •.Metal.clevis.(2). •.4-40.nut.(2) •.Control.horn.connector.(2). •.1/4-inch.tubing.(2) •.6 -inch.(165mm).pushrod.linkage.(2) •.8-32.x.2 -inch.countersunk.screw.(2) •.Elevator.(right.and.left) •.4-40.x.3/8-inch.socket.head.screw Required Tools and Adhesives •.Ruler. •.Felt-tipped.pen •.Drill. •.4-40.tap  .Step 3 •.Tap.handle •.18-inch.(458mm).servo.extension.(2) Mark.the.tube.at.the.fuselage.using.a.felt-tipped.pen. •.Hex.wrench:.3/32-inch •.Drill.bit:.3/32-inch.(2.5mm).or.#43 ...
  • Page 19 Stabilizer Installation   .Step 5 .Step 7 Tap.the.hole.made.in.the.previous.step.using.a.4-40.tap. Slide.the.short.stabilizer.tube.into.the.hole.in.the.. stabilizer.toward.the.leading.edge..Slide.the.assembly.. into.the.fuselage.  .Step 6 Secure.the.tube.using.a.4-40.x.3/8-inch.socket.head.  .Step 8 screw.and.#4.washer. Slide.the.remaining.stabilizer.onto.the.tubes..Press.. the.two.stabilizers.tight.against.the.fuselage..Repeat.. Steps.4.through.6.to.secure.the.stabilizer.to.the.tubes.. and.in.the.fuselage.
  • Page 20 Stabilizer Installation   .Step 9 .Step 15 Secure.an.18-inch.servo.extension.to.each.of.the.elevator. Assemble.the.elevator.linkage.using.the.6 -inch.. servos..Install.the.servos.into.the.fuselage..Install.large. control.rod,.clevis,.4-40.nut.and.1/4-inch.(4mm).tubing. control.horns.on.the.servos.in-line.with.each.other. and.control.horn.connector.as.shown..The.length.of.the. linkage.will.be.approximately.7 -inch.(184mm).  .Step 10  .Step 11 Install.the.8-32.x.2 -inch.countersunk.screw.and.secure. it.using.an.8-32.flanged.nut..Use.threadlock.on.the.screw. Thread.the.control.horn.connector.onto.the.countersunk. and.nut.to.prevent.vibrations.from.loosening.the.nut. screw.so.the.distance.between.the.control.surface.and. bottom.of.the.connector.is.7/8-inch.(22mm).

  • Page 21: Engine.and.receiver.installation.(Gas)

    Stabilizer Installation   .Step 12 .Step 13 Install.the.6 -inch.(165mm).pushrods.to.operate.. Replace.the.hatch.back.onto.the.fuselage.to.cover.. the.elevator..Attach.the.clevis.to.the.control.horn.so.it.is. the.servos. 3/4-inch.(19mm).from.the.center.of.the.servo.arm. Engine and Receiver Installation (Gas) Required Parts  .Step 1 •.Fuselage.assembly. •.Fuel.tank Position.the.engine.mount.template.onto.the.front.of. •.Engine.mount.(right.and.left) the.fuselage..Use.a.1/16-inch.drill.bit.to.drill.pilot.holes. through.the.template.and.into.the.firewall. •.Engien.mount.template Required Tools and Adhesives •.Drill. •.8-32.blind.nut.(4) •.1/4-inch.fuel.tubing.(3). •.#4.washer.(3) •.#8.washer.(12). •.8-32.lock.nut.(4) •.Threadlock •.Soldering.iron.
  • Page 22   .Step 2 .Step 4 Remove.the.template.from.the.fuselage..Use.a.. Attach.the.engine.using.four.8-32.x.1 -inch.. 13/64-inch.drill.bit.to.enlarge.the.holes.so.the.blind.. machine.screws,.eight.#8.washers.and.four.8-23.. nuts.can.be.installed. lock.nuts..Position.the.engine.so.the.drive.washer.is.. .inches.(150mm).forward.of.the.firewall.before.. tightening.the.screws.  .Step 3 Attach.the.engine.mount.to.the.firewall.using.four.. 8-32.x.1-inch.machine.screws,.four.#8.washers.and.. four.8-32.blind.nuts..Use.threadlock.on.the.screws.to. prevent.vibrations.from.loosening.the.screws.  .Step 5 Attach.the.igintion.module.to.the.bottom.of.the.engine.box. using.#4.x.1/2-inch.sheet.metal.screws.and.#4.washers.. This.hardware.is.not.included.with.your.Sundowner. Note:.The.arrows.on.the.engine.mounts. will.face.the.opening.for.the.throttle. servo.when.installed.correctly.
  • Page 23   .Step 6 .Step 8 Attach.a.6-inch.servo.extension.to.the.throttle.servo..Drill. Plug.the.rudder,.elevator,.throttle.and.any.other.. a.hole.in.the.engine.box.to.route.the.the.ignition.battery. extension.into.the.receiver..Wrap.the.receiver.in.foam.. lead..Route.the.ignition.module.lead.through.the.hole. and.secure.it.inside.the.fuselage..A.tube.has.been.. and.into.the.fuselage..Mount.the.throttle.servo.using.the. installed.inside.the.fuselage.so.the.antenna.can.be.. hardware.provided.with.the.servo. routed.through.the.fuselage. Note:.Never.cut.the.antenna.on.your. Note:.Always.keep.the.power.lead.from. receiver..This.will.greatly.reduce.the. the.ignition.module.away.from.the.radio. range.of.your.radio.system. system.to.avoid.any.radio.interference. Note:.The.following.steps.are.necessary.when.  .Step 7 installing.a.gas.engine..Failure.to.change. Connect.the.throttle.linkage.to.the.carburetor.of.your. the.fuel.lines.and.secure.them.properly. engine..Connect.any.items.from.the.ignition.module.to.. may.cause.your.engine.to.stop.in.flight. the.engine.at.this.time.as.well.  .Step9 Remove.the.stopper.from.the.fuel.tank.using.a.Phillips. screwdriver..Remove.the.fuel.lines.from.the.stopper.and. set.them.aside..Prepare.the.tubing.by.placing.a.drop.of. solder.on.the.ends.of.the.brass.tubing.as.shown..This. will.keep.the.fuel.line.from.slipping.off.the.tube.when. combined.with.the.following.steps.
  • Page 24   .Step 10 .Step 12 Slide.gas.compatible.fuel.lines.back.onto.the.brass.. Slide.the.fuel.tank.into.position.inside.the.fuselage..Guide. tubes..Use.fine.wire.to.secure.the.fuel.lines..The.wire.. the.fuel.lines.through.the.opening.in.the.firewall.while. is.placed.behind.the.solder.applied.in.the.previous.step.. installing.the.tank..Secure.the.rear.of.the.fuel.tank.with.the. to.keep.the.tubes.in.place. supplied.piece.of.plywood.  .Step 11 Carefully.insert.the.stopper.assembly.into.the.fuel.tank.. Note.the.position.of.the.vent.tube;.it.must.be.up.at.the.top. portion.of.the.fuel.tank.to.function.properly..Tighten.the.  .Step 13 3mm.x.20.screw.carefully—do.not.over-tighten. Connect.the.line.from.the.clunk.to.the.carburetor..The.. vent.line.will.be.directed.toward.the.bottom.of.the.. fuselage.and.secured.so.it.won't.interfere.with.the. operation.of.the.engine. Note:.We.used.a.fuel.dot.and.T-fitting. on.our.model.so.the.cowl.won't.have. to.be.removed.to.fuel.the.engine.
  • Page 25  .Step 14 Install.the.receiver.battery.and.the.battery.for.the.ignition. module.at.this.time..Make.sure.both.are.secure.and.will. not.move.in.flight.  .Step 16 Slide.a.#4.washer.and.a.1/4-inch.piece.of.fuel.tubing.. onto.each.of.the.two.4-40.x.1-inch.socket.head.screws. and.the.4-40.x.1/2-inch.socket.head.screw..Slide.the. cowling.into.position.and.trim.as.necessary.to.clear.any. Note:.The.location.of.the.receiver.and. part.of.the.engine.or.exhaust.system..Mount.the.fuel.dot. ignition.battery.may.vary.depending.on. so.it.can.be.easily.accessed.and.won't.interfere.with.any. the.engine.used.and.the.size.of.the.battery. part.of.the.engine.inside.the.cowling..Secure.the.cowl. used..Feel.free.to.locate.the.batteries.as. using.the.1-inch.socket.head.screws.on.the.sides.and.the. necessary.to.correctly.balance.your.model. 1/2-inch.screw.on.the.top.of.the.cowling..Complete.the. engine.installation.by.installing.the.propeller.and.spinner.  .Step 15 onto.the.engine. Attach.the.muffler.to.your.engine.

  • Page 26: Engine.and.receiver.installation.(Glow)

    Engine and Receiver Installation (Glow) Required Parts  .Step 2 •.Fuselage.assembly. •.Fuel.tank Remove.the.template.from.the.fuselage..Use.a.. •.Engine.mount.template 13/64-inch.drill.bit.to.enlarge.the.holes.so.the.blind.. nuts.can.be.installed. •.Engine.mount.(right.and.left) Required Tools and Adhesives •.Drill. •.8-32.blind.nut.(4) •.1/4-inch.fuel.tubing.(3). •.#4.washer.(3) •.#8.washer.(12). •.8-32.lock.nut.(4) •.Threadlock •.2 .(54mm).threaded.rod •.Rotary.tool.w/sanding.drum •.8-32.x.1-inch.machine.screw.(4) •.2-56.ball.link.end.w/hardware.(2) •.8-32.x.1 -inch.machine.screw.(4)  .Step 3 •.4-40.x.1/2-inch.socket.head.screw Attach.the.engine.mount.to.the.firewall.using.four.. •.4-40.x.1-inch.socket.head.screw.(2) 8-32.x.1-inch.machine.screws,.four.#8.washers.and..
  • Page 27 Engine and Receiver Installation   .Step 4 .Step 6 Attach.the.engine.using.four.8-32.x.1 -inch.. Assemble.a.throttle.pushrod.using.two.2-56.ball.. machine.screws,.eight.#8.washers.and.four.8-32.. ends.and.a.2 -inch.(54mm).piece.of.2-56.threaded.. lock.nuts..Position.the.engine.so.the.drive.washer.is.. rod..The.length.of.the.linkage.will.be.approximately.. .inches.(150mm).forward.of.the.firewall.before.. -inch.(90mm). tightening.the.screws.  .Step 7 Note:.You.may.need.to.rotate.the. Connect.the.throttle.linkage.between.the.carburetor.of.your. carburetor.on.your.particular.engine.so. engine.and.the.servo.arm..Adjust.the.length.of.the.linkage. the.throttle.arm.faces.down.to.align.with. as.necessary. the.notch.made.in.the.engine.box.  .Step 5 Attach.a.6-inch.servo.extension.to.the.throttle.servo.. Mount.the.throttle.servo.using.the.hardware.provided.. with.the.servo. Note:.Use.threadlock.on.all.metal- to-metal.fasteners.to.prevent.them. from.vibrating.loose.in.flight.
  • Page 28 Engine and Receiver Installation   .Step 8 .Step 10 Plug.the.rudder,.elevator,.throttle.and.any.other.. Connect.the.line.from.the.clunk.to.the.carburetor..The.vent. extension.into.the.receiver..Wrap.the.receiver.in.foam.. line.will.be.attached.once.the.muffler.has.been.installed. and.secure.it.inside.the.fuselage..A.tube.has.been.. installed.inside.the.fuselage.so.the.antenna.can.be.. routed.through.the.fuselage. Note:.We.used.a.fuel.dot.and.T-fitting. on.our.model.so.the.cowl.won't.have. to.be.removed.to.fuel.the.engine. Note:.Never.cut.the.antenna.on.your. receiver..This.will.greatly.reduce.the. range.of.your.radio.system.  .Step 9 Slide.the.fuel.tank.into.position.inside.the.fuselage..Guide. the.fuel.lines.through.the.opening.in.the.firewall.while. installing.the.tank..Secure.the.rear.of.the.fuel.tank.with.the. supplied.piece.of.plywood.
  • Page 29 Engine and Receiver Installation   .Step 11 .Step 13 Install.the.receiver.battery.at.this.time..Make.sure.it.is. Slide.a.#4.washer.and.a.1/4-inch.piece.of.fuel.tubing.. secure.and.will.not.move.in.flight. onto.each.of.the.two.4-40.x.1-inch.socket.head.screws. and.the.4-40.x.1/2-inch.socket.head.screw..Slide.the. cowling.into.position.and.trim.as.necessary.to.clear.any. part.of.the.engine.or.exhaust.system..Mount.the.fuel.dot. so.it.can.be.easily.accessed.and.won't.interfere.with.any. part.of.the.engine.inside.the.cowling..Secure.the.cowl. using.the.1-inch.socket.head.screws.on.the.sides.and.the. 1/2-inch.screw.on.the.top.of.the.cowling..Complete.the. engine.installation.by.installing.the.propeller.and.spinner. onto.the.engine.  .Step 12 Attach.the.muffler.to.your.engine..Connect.the.vent.line.to. the.muffler.at.this.time.

  • Page 30: Final.assembly

    Final Assembly Required Parts  .Step 3 •.Wing.panel.(left.and.right). •.Wing.tube Slide.the.tube.into.the.fuselage.while.guiding.the.aileron. •.Canopy.hatch. •.Pilot.head servo.lead.through.the.hole.in.the.side.of.the.fuselage. •.1/4-20.x.1 -inch.wing.bolt.(2) Required Tools and Adhesives •.30-minute.epoxy •.Medium.grit.sandpaper  .Step 1 Locate.the.pilot.head..Roughen.the.bottom.of.the.head. using.medium.grit.sandpaper..Use.30-minute.epoxy.to. glue.the.head.into.the.cockpit.  .Step 4 Secure.the.wing.panel.to.the.fuselage.using.a.. 1/4-20.x.1 -inch.wing.bolt.  .Step 2 Slide.the.wing.tube.into.one.of.the.wing.panels.  .Step 5 Slide.the.remaining.wing.panel.onto.the.wing.tube..Secure.

  • Page 31: Recommended.center.of.gravity.(Cg)

    Final Assembly  .Step 6 Install.the.canopy.hatch.back.in.position.on.the.fuselage.. Secure.it.using.the.two.4-40.socket.head.screws.that.were. previously.installed.to.hold.the.canopy.hatch. Recommended Center of Gravity (CG) An.important.part.of.preparing.the.aircraft.for.flight.is. The.recommended.Center.of.Gravity.(CG).location.. properly.balancing.the.model..This.is.especially.important. for.the.Sundowner.is.CG:.3 .inches.(82mm).back.. when.various.engines.are.mounted. from.leading.edge.of.wing.at.the.root.rib..Make.sure.the. aircraft.is.inverted.when.measuring.the.CG..If.necessary,. Caution:.Do.not.inadvertently.skip.this.step! move.the.receiver.or.ignition.(if.using.a.gas-powered. engine).battery.pack.or.add.weight.to.either.the.nose.or. the.tail.until.the.correct.balance.is.achieved..Stick-on. weights.are.available.at.your.local.hobby.store.and.work. well.for.this.purpose..The.CG.Range.for.your.Sundowner. is.3–3 .inches.(76mm–89mm).back.from.leading.edge. of.wing.at.the.root.rib.

  • Page 32: Control.throws

    Control Throws Rudder: The.amount.of.control.throw.should.be.adjusted.as.closely. as.possible.using.mechanical.means,.rather.than.making. High.Rate:. 15/16-inch.(24mm).left/right large.changes.electronically.at.the.radio..By.moving. 25.degrees.left/right the.position.of.the.clevis.at.the.control.horn.toward.the. 15%.Exponential outermost.hole,.you.will.decrease.the.amount.of.control. Low.Rate:. 7/16-inch.(11mm).left/right throw.of.the.control.surface:.moving.it.toward.the.control. 12.degrees.left/right surface.will.increase.the.amount.of.throw;.moving.the. 7%.Exponential pushrod.wire.at.the.servo.arm.will.have.the.opposite. effect..Moving.it.closer.to.center.will.decrease.throw,. Note:.Rudder.throw.is.measured. and.away.from.center.will.increase.throw..Work.with.a. at.the.bottom.of.the.rudder. combination.of.the.two.to.achieve.the.closest.or.exact. control.throws.listed. Once.the.control.throws.have.been.set,.slide.the.clevis. retainers.over.the.clevis.to.prevent.them.from.opening. Aileron: during.flight. High.Rate:. 5/8-inch.(16mm).up/down 15.degrees.up/down 15%.Exponential Low.Rate:. 5/16-inch.(8mm).up/down 8.degrees.up/down 7%.Exponential Note:.Aileron.throw.is.measured.at.the.trailing. edge.of.the.aileron.nearest.the.fuselage. Elevator: High.Rate:.

  • Page 33: Pre-Flight

    Pre-Flight Charge.both.the.transmitter.and.receiver.pack.for.your.airplane..Use.the.recommended.charger.supplied.with.your. particular.radio.system,.following.the.instructions.provided.with.the.radio..In.most.cases,.the.radio.should.be.charged.the. night.before.going.out.flying. Check.the.radio.installation.and.make.sure.all.the.control.surfaces.are.moving.correctly.(i.e..the.correct.direction.and.with. the.recommended.throws)..Test.run.the.engine.and.make.sure.it.transitions.smoothly.from.idle.to.full.throttle.and.back.. Also.ensure.the.engine.is.tuned.according.to.the.manufacturer’s.instructions,.and.it.will.run.consistently.and.constantly.at. full.throttle.when.adjusted. Check.all.the.control.horns,.servo.horns.and.clevises.to.make.sure.they.are.secure.and.in.good.condition..Replace.any. items.that.would.be.considered.questionable..Failure.of.any.of.these.components.in.flight.would.mean.the.loss.of.your. aircraft. Adjusting the Engine  .Step 1 Completely.read.the.instructions.included.with.your.engine.and.follow.the.recommended.break-in.procedure.  .Step 2 At.the.field,.adjust.the.engine.to.a.slightly.rich.setting.at.full.throttle.and.adjust.the.idle.and.low-speed.needle.so.that.a. consistent.idle.is.achieved.  .Step 3 Before.you.fly,.be.sure.that.your.engine.idles.reliably,.transitions.and.runs.at.all.throttle.settings..Only.when.this.is. achieved.should.any.plane.be.considered.ready.for.flight. Range Test Your Radio Before.each.flying.session,.be.sure.to.range.check.your.radio..See.your.radio.manual.for.the.recommended.range.and. instructions.for.your.radio.system..Each.radio.manufacturer.specifies.different.procedures.for.their.radio.systems..If.using. a.gasoline.engine,.check.the.range.first.with.the.engine.not.running.and.note.the.distance..Next,.start.the.engine..With.the. model.securely.anchored,.check.the.range.again..The.range.test.should.not.be.significantly.affected..If.it.is,.don’t.attempt. to.fly!.Have.your.radio.equipment.checked.out.by.the.manufacturer.

  • Page 34: 2007.Official.ama.national.model.aircraft.safety.code

    2007 Official AMA National Model Aircraft Safety Code GENERAL 7).I.will.not.operate.models.with.pyrotechnics.(any. device.that.explodes,.burns,.or.propels.a.projectile. 1).I.will.not.fly.my.model.aircraft.in.sanctioned. of.any.kind).including,.but.not.limited.to,.rockets,. events,.air.shows.or.model.flying.demonstrations.until. explosive.bombs.dropped.from.models,.smoke. it.has.been.proven.to.be.airworthy.by.having.been. bombs,.all.explosive.gases.(such.as.hydrogen-filled. previously,.successfully.flight.tested. balloons),.or.ground.mounted.devices.launching.a. 2).I.will.not.fly.my.model.higher.than.approximately. projectile..The.only.exceptions.permitted.are.rockets. 400.feet.within.3.miles.of.an.airport.without.notifying. flown.in.accordance.with.the.National.Model.Rocketry. the.airport.operator..I.will.give.right-of-way.and.avoid. Safety.Code.or.those.permanently.attached.(as.per. flying.in.the.proximity.of.full-scale.aircraft..Where. JATO.use);.also.those.items.authorized.for.Air.Show. necessary,.an.observer.shall.be.utilized.to.supervise. Team.use.as.defined.by.AST.Advisory.Committee. flying.to.avoid.having.models.fly.in.the.proximity.of. (document.available.from.AMA.HQ)..In.any.case,. full-scale.aircraft. models.using.rocket.motors.as.a.primary.means.of. 3).Where.established,.I.will.abide.by.the.safety.rules. propulsion.are.limited.to.a.maximum.weight.of.3.3. for.the.flying.site.I.use,.and.I.will.not.willfully.and. pounds.and.a.G.series.motor..(A.model.aircraft.is. deliberately.fly.my.models.in.a.careless,.reckless.and/ defined.as.an.aircraft.with.or.without.engine,.not.able. or.dangerous.manner. to.carry.a.human.being.) 4).The.maximum.takeoff.weight.of.a.model.is.55.
  • Page 35 2007 Official AMA National Model Aircraft Safety Code 5).Flying.sites.separated.by.three.miles.or.more. Organized RC Racing Event are.considered.safe.from.site-to.site.interference,. 10).An.RC.racing.event,.whether.or.not.an.AMA.Rule. even.when.both.sites.use.the.same.frequencies..Any. Book.event,.is.one.in.which.model.aircraft.compete. circumstances.under.three.miles.separation.require. in.flight.over.a.prescribed.course.with.the.objective.of. a.frequency.management.arrangement,.which.may. finishing.the.course.faster.to.determine.the.winner. be.either.an.allocation.of.specific.frequencies.for. A..In.every.organized.racing.event.in.which. each.site.or.testing.to.determine.that.freedom.from. contestants,.callers.and.officials.are.on.the.course: interference.exists..Allocation.plans.or.interference. 1..All.officials,.callers.and.contestants.must.properly. test.reports.shall.be.signed.by.the.parties.involved. wear.helmets,.which.are.OSHA,.DOT,.ANSI,.SNELL.or. and.provided.to.AMA.Headquarters..Documents.of. NOCSAE.approved.or.comparable.standard.while.on. agreement.and.reports.may.exist.between.(1).two. the.racecourse. or.more.AMA.Chartered.Clubs,.(2).AMA.clubs.and. 2..All.officials.will.be.off.the.course.except.for.the. individual.AMA.members.not.associated.with.AMA. starter.and.their.assistant. Clubs,.or.(3).two.or.more.individual.AMA.members. 3.”On.the.course”.is.defined.to.mean.any.area.beyond. 6).For.Combat,.distance.between.combat.engagement. the.pilot/staging.area.where.actual.flying.takes.place.
  • Page 36 ©.2007.Horizon.Hobby,.Inc.. 4105.Fieldstone.Road. Champaign,.Illinois.61822. (877).504-0233. horizonhobby.com 10243...

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