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GREAT PLANES Ultimate 40 Instruction Manual
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GREAT PLANES Ultimate 40 Instruction Manual

GREAT PLANES Ultimate 40 Instruction Manual

Great planes ultimate 40 biplane rc airplane kit
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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 buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised
to return this kit immediately in new and unused condition to the place of purchase.
While this kit has been flight tested to exceed normal use, if the plane will be used for extremely high stress flying, such
as racing, the modeler is responsible for taking steps to reinforce the high stress points.
READ THROUGH THIS MANUAL BEFORE
STARTING CONSTRUCTION. IT CONTAINS
IMPORTANT WARNINGS AND INSTRUCTIONS
CONCERNING THE ASSEMBLY AND USE OF
THIS MODEL.
©Copyright 1998
WARRANTY
P.O. Box 788
Urbana, IL 61803
(217) 398-8970
ULT4P03 V1 1

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Summary of Contents for GREAT PLANES Ultimate 40

  • Page 1 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.
  • Page 2 Build the Fuselage ............18 Fuselage Preassembly..........18 Assemble the Fuselage Sides ........19 Your Ultimate 40 is not a toy, but rather a sophisticated, working model that functions very much like a full size Install the Formers .............20 Mount the Wing on the Fuselage.......22...
  • Page 3 R/C flying, and you are able to safely handle a 40-size low wing airplane, the Ultimate 40 is an excellent choice to try your skills at flying a biplane. You must assemble the model according to the...
  • Page 4 These are the building tools that are required. We recommend Great Planes Pro" CA and Epoxy glue. D 2 oz. Pro CA (Thin, GPMR6003) D 2 oz Pro CA+ (Medium, GPMR6009) D 1 oz Pro CA- (Thick, GPMR6014) D 6-Minute Pro Epoxy (GPMR6045)
  • Page 5 There are two types of screws used in this kit. D 1. Unroll the plan sheets Reroll the plan sheets inside out to make them lie flat Place wax paper or Great Planes Sheet metal screws are designated by a number and a Plan Protector over the plan to prevent glue from sticking to length.
  • Page 8 Glue together the pairs of die-cut 1/8" balsa stabilizer center S-1, fin bottom S-2, rudder bottom R-3 and rudder tip R-4 to make 1/4" thick parts. D 3 Remove the stab from your building board Inspect all the glue joints and add CA to any joints that don't look strong Sand the LE and TE flush Sand the entire top and bottom surfaces of the stab until they are flat and even Be careful that you don't sand any area of the stab too thin.
  • Page 9 D 3. Remove the fin from your building board. Inspect all the glue joints and add CA to any joints that don't look strong. Sand the joints flush and the entire top and bottom surfaces of the fin flat and even. Be careful that you don't sand any area too thin.
  • Page 10 D 4. Cut the hinges for the elevators and rudder from the supplied 2" x 9" hinge material. Use the hinge drawing on the fuse plan as a guide. Trim off the corners and D 1. Place the stab and elevators over their locations on temporarily join the elevators to the stabs with the hinges, the plan and lightly mark the hinge locations on the TE of adjusting any hinge slots if necessary.
  • Page 11 D 3 Draw a centerline on the LE of the stab and fin and on the TE and tip of the elevators and rudder Sand a radius on the edges as shown on the plan using the centerline as a guide to keep the radius symmetrical Do not round the TE of the stab or fin.
  • Page 12 D 1. Pin the die-cut 3/32" balsa ribs R-1 in position over The Ultimate 40 bottom wing is built as one piece. the main spar. Note: The jig tabs should be contacting the plan. Use small T-pins to pin the aft jig tabs to the building board over their location on the plan.
  • Page 13 D 6. Position the TE on the aft end of the ribs, flush with the top and bottom edge of the ribs. Use a straightedge to D 11. Glue the die-cut 3/32" balsa ribs R-4 flush with both check that the TE is straight before gluing it in position. sides of R-5.
  • Page 14 D 15 Test fit the die cut 1/8" plywood ribs R-2A and R-2B in position as shown on the plans Check the fit of the wing strut between R-2A and the wing spars The strut should fit snug but be easy to insert and remove When satisfied with the fit, remove the strut and glue ribs R-2A and R-2B D 1.
  • Page 15 D 9. From 1/16" x 3/16" x 30" balsa stick, cut and glue cap strips to the top of the R-1 ribs. The edge of the cap strip D 5. Use thin CA to glue the LE sheet to the main spar. on the R-1 tip rib should be flush with the side of the rib.
  • Page 16 D 3. Position the wing on your building board with the bottom side up. Place weights on the wing to keep the main spars in contact with the building board. Glue the bottom LE sheeting in position following the same procedure used for the top LE sheeting.
  • Page 17 the wing plate. Leave the aft edge of the wing bolt plate square Use 30-mmute epoxy to glue the wing bolt plate to the bottom of the wing, centered on the center TE The aft corners of the wing bolt plate are flush with the aft end of the center TE.
  • Page 18 D D 8. Remove the aileron from the wing. Mark the "bevel to" lines and sand the LE of the aileron to a "V" as shown D 2. Glue the die-cut 1/16" birch plywood F-8A doubler to on the plan. the front of the die-cut 1/8"...
  • Page 19 D 6. Cut 1/4" from the front of one die-cut 1/8" balsa lower D 1. Build two fuse sides by gluing together the balsa lower and upper fuse sides. Make sure to glue the two fuse side, one upper fuse side, one die-cut 1/8" plywood lower fuse doubler and one upper fuse doubler.
  • Page 20 Important: Install all formers with the embossed lettering facing the nose of the fuse. Do not glue the fuse together until instructed to. D 4. Install the die-cut 1/8" plywood formers F-9, F-8A/B and the firewall as you pull the fuse sides together. You may need to use clamps, placed along the bottom of the fuse, along with rubber bands to hold the sides together.
  • Page 21 D 13. Remove the landing gear. Use 6-minute epoxy to glue the die-cut 1/8" plywood landing gear back plate D 9. Fit the die-cut 1/8" plywood landing gear braces F-4, F-7 and the 1/4" plywood landing gear plate in the fuse (FB-3) to the fuse sides, F-7 and F-8A/B.
  • Page 22 D 22. Glue a piece of 1/8" x 1/4" balsa stick under the D 18. Use 6-minute epoxy to glue the fuel tank floor, forward edge of the bottom deck. fuelproofed side down, into the notches in the lower fuse doubler.
  • Page 23 D 3. Final sand the stab and fin. D 4. Draw an accurate centerline on the top of the stab, perpendicular to the stab TE. D 3. With the wing in position, drill a 13/64" hole at each punch mark on the wing bolt plate. The hole must extend through the wing and wing bolt plate, perpendicular to the bottom surface of the wing.
  • Page 24 D 5. Wet the outside of the turtledeck sheeting with warm water, allowing it to soak in for a few minutes. Position the D 1. Use the die-cut 1/8" plywood backrest gauge to set the sheets on the top of the fuse against the bottom of the angle of the backrest.
  • Page 25 D 9. Carve and sand the turtledeck top to match the curve of the turtledeck sheeting. Refer to the cross-section drawings on the fuse plan. Trim and sand the forward end D 1. Glue the die-cut 1/8" balsa former F-5 and the flush with the front of the backrest.
  • Page 26 D 5. Use a 1/16" drill bit to drill a hole through the quarter D 10. Center the die-cut 1/8" plywood tank hatch over the round at the marks on the longitudinal braces for the cabane slots. After locating the slots, use a hobby knife or opening in front of the top deck.
  • Page 27 D 3. Use 30-minute epoxy to glue the W-2 bolt plates, centered over the hole in the W-3 bolt plates. D 13. From the leftover 1/8" x 1/4" balsa sticks, make cockpit sides to fit between the IP and the backrest. Glue the cockpit sides in position, flush with the fuse sides.
  • Page 28 D 4. Repeat the process to install the other LE. D 10. Trim the leftover LE to fit between the installed LE. When satisfied with the fit, glue it in place. D 5. Position the TE on the aft end of the ribs, flush with the top and bottom edge of the ribs.
  • Page 29 D 14 From a 1/16" x 3" x 24" balsa sheet, cut and glue shear webs, perpendicular to the aft edge of the main spars The shear webs must be glued securely to the main spars D 21 Test fit ribs R-8 in position between the LE and the D 15 Sand the top of the wing so that the spars, shear wing joiner Lightly sand the inside of the TE to allow ribs webs and TE are flush with the top of the ribs.
  • Page 30 D 25. After positioning the top wing in its proper location, place alignment marks on the front bolt plates, ribs R-8, the wing joiner and the LE. Remove the wing and use 30-minute epoxy to glue ribs R-8 and the front bolt plates to the LE, wing joiner and ribs R-7.
  • Page 31 D 1. Remove the top wing from the fuse and pin or weight it flat on your building board. Make sure all the forward and aft jig tabs are against the building board. Sand the top of the ribs flush with the TE. D 6.
  • Page 32 D 14. Finish sand the strut with 320-grit sandpaper. Glue the strut brace along the centerline of the strut from base D 7. Make the wing tips from leftover 1/8" x 3" x 18" balsa line to base line. Install the strut braces on both sides of sheet.
  • Page 33 D 1. Cut the "spreader bar" from the supplied Great Planes engine mount. Use a hobby knife to remove any flashing so the halves fit together properly. D 2. Temporarily mount the engine mount to the firewall with four 6-32 x 1" machine screws and #6 washers. Do not tighten the screws all the way so you can adjust the mount.
  • Page 34 goes over the lip of the inner pant and the bottom of the inner C. Remove the engine from the engine mount and the pant goes over the lip of the outer pant. You can use a hobby mount from the fuse. Use a drill press, if you have one, knife to carefully score along the cut lines and flex the plastic to drill a 1/16"...
  • Page 35 D 7. Use a metal file to chamfer the edges and corners of B. Use a 9/64" hex wrench to thread the socket head screw the aluminum landing gear so it will fit neatly in the recess through the wheel pant until the wheel goes in and the of the wheel pant.
  • Page 36 D 14. After the filler cures, sand it flush with the plastic. Wet sand the entire wheel pant with 400-grit sandpaper in preparation for primer. Note: Don't forget to reinforce the joints with fiberglass cloth and CA. D 5. Slide the cowl over the engine and fuselage. Reinstall D 1.
  • Page 37 HobbyLite ' balsa colored filler. D 10 On our prototype Ultimate we made a mount for the Great Planes Easy Fueler from 1/8" leftover plywood and securely glued it to the side of the fuselage We cut an access Here is an easy method to remove minor dents in wood hole in the cowl for the fueler using the template method.
  • Page 38 Fuselage and Tail: 1 1/4" strips at fin and stab as described 2 Aft fuselage bottom 3 Forward fuselage bottom 1 Starting with the elevators and stab, cut the covering 4 Fuselage right side up to the top center of the turtle from the hinge slots deck and center of nose 5.
  • Page 39 (not included) on the tank floor Insert the fuel tank installing This pin will keep the hinge centered while you into the fuel tank compartment If using the Great Planes install the control surfaces. 10oz fuel tank place a piece of foam padding at the front of...
  • Page 40 D 4 Without cutting into the balsa, use a sharp hobby knife to carefully cut and remove a strip of covering 1/16" wide, approximately 1/32" inside of the line you made Wipe away the line with a paper towel dampened with alcohol. D 5 Reposition the canopy on the fuse and confirm that it covers the exposed wood Glue the canopy to the fuse with a glue formulated for gluing on canopies such as Pacer...
  • Page 41 D 7. Slide a silicone retainer over the threaded end of two 36" threaded pushrods. Thread a nylon clevis 13 turns D 10. Disconnect the clevises from the control horns and onto each pushrod. Slide the pushrods into the rudder and make a 90' bend at the marks you made.
  • Page 42 D D 16 Thread a nylon clevis 13 turns onto the end of a 12" threaded pushrod. Attach the clevis to the control horn on the top wing aileron. D 13. Install the aileron servo in the aileron servo tray. Thread the nylon 6-32 torque rod connectors on the torque rods until they are 3/4"...
  • Page 43 4-CHANNEL RADIO SETUP (STANDARD MODE 2) ELEVATOR MOVES UP D D 19. Slide a silicone retainer on the pushrod. Use a RIGHT AILERON MOVES UP 5/64" or #48 drill bit to enlarge the hole in the control horn LEFT AILERON MOVES DOWN on the bottom aileron only.
  • Page 44 Note: Nose weight may be easily installed by using a unstable and possibly unflyable. "spinner weight" or gluing lead weights to the firewall Tail weight may be added by using Great Planes (GPMQ4485) "stick-on" lead weights. At this time check all connections including servo horn screws, clevises, servo cords and extensions Make sure D 1 The balance point (C.G.) is located 2-3/8"...
  • Page 45 Note: Failure to follow these safety precautions may result in severe injury to yourself and others. Since you have chosen the Ultimate 40, we assume that you are an experienced modeler Therefore, you should Keep all engine fuel in a safe place, away from high heat,...
  • Page 46 7 I will not fly my model unless it is identified with my The Great Planes Ultimate 40 is a great flying biplane that name and address or AMA number, on or in the model.
  • Page 47 43. Sometimes well before it's time to land, you should climb your Ultimate 40 to a safe altitude, cut the throttle to an idle and check out the model's low speed characteristics. Do this a few times so you know what to expect upon landing and how the Ultimate 40 handles stalls.
  • Page 48 TWO VIEW Photocopy this drawing and use the copies to design your trim scheme. PRINTED IN USA 3005155...