GREAT PLANES Super Decathlon 40 Instruction Book
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GREAT PLANES Super Decathlon 40 Instruction Book

GREAT PLANES Super Decathlon 40 Instruction Book

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PLEASE READ THROUGH THIS INSTRUCTION BOOKLET IN ITS ENTIRETY BEFORE BEGINNING
ASSEMBLY. IT CONTAINS IMPORTANT INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY
AND USE OF THIS MODEL.
This R/C kit and the model you will build is not a toy! It is capable of serious bodily
harm and property damage. IT IS YOUR RESPONSIBILITY AND YOURS ALONE - to
build this kit correctly, properly install all R/C components and flying gear (engine, tank,
pushrods, etc.) and to test the model and fly it only with experienced, competent help, using
common sense and in accordance with all safety standards as set down in the Academy of Model
Aeronautics Safety Code. It is suggested that you join the AMA to become properly insured
before you attempt to fly this model. IF YOU ARE JUST STARTING R/C MODELING,
CONSULT YOUR LOCAL HOBBY SHOP OR WRITE TO THE ACADEMY OF MODEL
AERONAUTICS TO FIND AN EXPERIENCED INSTRUCTOR IN YOUR AREA.
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302-9252 (800) 435-9262
INSTRUCTION BOOK
WARNING! THIS IS NOT A TOY!
DE40P03

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Summary of Contents for GREAT PLANES Super Decathlon 40

  • Page 1 INSTRUCTION BOOK PLEASE READ THROUGH THIS INSTRUCTION BOOKLET IN ITS ENTIRETY BEFORE BEGINNING ASSEMBLY. IT CONTAINS IMPORTANT INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL. WARNING! THIS IS NOT A TOY! This R/C kit and the model you will build is not a toy! It is capable of serious bodily harm and property damage.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Install "2-cycle firewall" ... . . 25 INTRODUCTION ....3 Drill Engine Mount .

  • Page 3: Introduction

    The Super Decathlon 40 is a 1/6-scale model of a full- size Bellanca Super Decathlon, owned by Pete Myers, lo- 5. You must test the operation of the model before the cated at Howell Airport in New Lenox, IL.

  • Page 4: Die Patterns

    DIE PATTERNS Use this drawing to help you identify the die cut parts...

  • Page 5: Decisions You Must Make Now

    .40* - .46 cubic inch displacement 2-cycle .48 - .70 cubic inch displacement 4-cycle NOTE: If you choose to power your Super Decathlon 40 *NOTE: Performance may be marginal if a non-schneurle- with a 4-cycle engine, keep in mind that the RPM of your ported .40 cu.in.

  • Page 6: Types Of Wood

    TYPES OF WOOD GET READY TO BUILD 1. Unroll the plan sheets. Re-roll the plans inside out to make them lie flat. 2. Remove all parts from the box. As you do, figure out the name of each part by comparing it with the plans and the parts list at the back of this book.

  • Page 7: Build The Fin

    hole is drilled slightly oversize to allow for positioning, and D 3. From the 1/4" x 1/2" x 30" sticks, cut "braces" to fit between the rudder framework, and glue them in place. to create a hard epoxy "sleeve" around the wire). Then groove the rudder leading edge to accept the tailgear wire .

  • Page 8: Build The Stabilizer

    D 2. Sand the elevator tips to the shape as shown on the BUILD THE STABILIZER plan. You'll need the following parts: D 3. Carefully draw a centerline all around the edges of 1/4" x 1" x 17-7/8" balsa suck the elevators.

  • Page 9: Install The Hinges

    NOTE: The following instructions explain how to build the wing directly on the plans. An alternate method is to use a Great Planes Wing Jig (available from your local D 1. Lay the rudder and elevators on the plan and mark hobby dealer).
  • Page 10 D 3. Before using the 3/8" x 3/8" x 32" hard balsa spars, examine them carefully for possible imperfections. Look for knots, soft spots, diagonal grain and any other imperfections. If possible, position each spar so the imperfections are on the outer half of the wing panel (toward the tip), where they will be least affected by high stress.
  • Page 11 15. Lightly sand the tops of the ribs to blend with the notched trailing edge; then glue one of the 3/32" x 1-1/4" 11. Insert the front ends of the ribs into the notches x 32" balsa trailing edge sheets in place. NOTE': The edge in the LE.

  • Page 12: Join The Wing Panels

    wing plan, and block up the trailing edge 1/2", using the 1/2" x 1/2" x 2" balsa blocks. Position the die-cut 1/8" ply dihedral gauge (DG) on the wing centerline, as shown in the photo, and mark cut-off lines on the spars, trailing edge and TE sheeting.

  • Page 13: Install Center Ribs And Sheeting

    INSTALL CENTER RIBS AND SHEETING D 1. Use a sanding block to sand off any excess epoxy on the top and bottom of the spars in the center of the wing. FILE END TO WEDGE SHAPE D 2. Roughen the surface of the plastic bearing tubes with 100-grit sandpaper.

  • Page 14: Fiberglass The Center Section

    use a scissors or a paper punch to cut holes in the glass cloth for the aileron torque rod horns. D 3. Wrap small pieces of masking tape around the exposed portions of the aileron torque rods to protect them from the spray adhesive in the next step.

  • Page 15: Install Wing Tips

    INSTALL WING TIPS NOTE: The wing tips will be cut and carved from the 1/4" x 1-3/4" x 11" balsa blocks. D 1. Draw a centerline on the ends of the wing and on the wing tip blocks. D 3. Hold the ailerons in place in the openings, with the torque rods resting on top of the ailerons.

  • Page 16: Temporarily Install Wing Dowels

    INSTALL WING BOLT PLATE There should be no hinge gap! Therefore, if you are using "pinned" hinges, you must D 1. Mark a centerline on the 1/16" x 3-1/2" x 1 -1/2" ply cut away balsa to make room for the center portion of the wing bolt plate.

  • Page 17: Fuselage Assembly

    sides "RIGHT" and "LEFT". From the front edge of both sides, accurately measure back 13/32" and draw a line sand them to blend with the surface of the wing. Poke several parallel with the front edge. holes with a pin near the center of the plate, apply thin CA, then sand smooth.
  • Page 18 the cross-braces (the formers are upside down), and sand the edges of the formers slightly to match the angle of the fuse sides. Glue the formers to the cross-braces, making sure that each former is installed perpendicular to the building surface.
  • Page 19 fit between the fuse sides. Use 30-minute or 5-minute epoxy to securely glue F-l to the fuse sides, holding with clamps or tape until the glue has firmly set. NOTE: Before the glue sets, double check to make sure F-l is properly aligned with the top edge of the fuselage, and fully back against the fuse doublers.

  • Page 20: Assemble Upper Fuselage

    and glue them to the top of F-1. The front of F-1T must line IMPORTANT NOTE: When performing steps 16-18, up with the front of F-1. it is possible that adding the triangles may have pulled the aft portion of the fuse out of alignment slightly. Check for this by positioning the fuse on the plan.
  • Page 21 edge and the rear window opening. Glue the doublers in place D 11. Securely glue the die-cut 1/8" ply F-2D to the making a RIGHT and a LEFT cabin side! tapered balsa filler and to the cabin sides. D 12. Find the 1/4" ply wing hold-down plate and trial fit it into the notches in the fuse side doublers, sanding as necessary for a good fit.
  • Page 22 two stringers 12" long. Cut these pieces to run from the notch TAPERED TAIL POST in front of F-5T to the aft edge of F-7T. Glue the stringers to , (Sand off flash with top F-5T, F-6T and F-7T, then sand to blend with the formers. of stab support) TAPERED TAIL POST (View from rear)

  • Page 23: Mount The Wing To The Fuse

    the holes in the dowel plate as a guide. Note: Drill only to a D 18. Glue the top rear sheeting to the top edge of the depth of 3/8", and try not to drill through F-2T. formers and stringers, beginning at the front of F-4T and running to the aft edge of F-7T.

  • Page 24: Mount Stabilizer And Fin

    D 17. Trial fit the wing to the fuse using the two 1/4-20 nylon bolts provided. You may cut the bolts off to their proper length, so they protrude about 1/4" below the hold-down blocks in the fuselage. Check the incidence of the wing using the instructions provided at the bottom of page 41.

  • Page 25: Final Assembly

    behind the fuselage and'' eyeballing" whether or not the stab tail filler for the bottom rudder hinge and the tailgear is level with the wing. Sand the stab saddle (a little at a time!) bearing. Trim off the bottom of the rudder, if necessary, to until it rests in proper alignment.

  • Page 26: Drill Engine Mount

    DRILL ENGINE MOUNT (Great Planes MM40 or MM60 mounts) D 1. Align the engine on the mount and mark the mount- ing hole locations on the mount. At the marked locations, accurately drill 7/64" (or #36) holes. NOTE: If you have access to a drill press, use it for drilling these holes to insure that they are drilled vertically.
  • Page 27 D 4. Mount the aileron servo using the screws provided D 10. Harden the balsa in the area of the control with your radio. horns (on both sides of the control surfaces) by poking several holes with a pin, then apply thin CA glue. Sand D 5.
  • Page 28 D 23. Securely anchor the pushrod guide tubes to F-4 using cross-braces cut from scrap 1/8" balsa. NOTE: The THROTTLE PUSHROD location will vary, depending on the engine used. Plan your installation carefully! D 15. Insert the plastic pushrod tubes through the holes you just cut and through formers F-7T, F-6T, F-5 and F-4.

  • Page 29: Control Surface Throws

    1/8" (to prevent puncturing the fuel tank). first flights with your Super Decathlon 40. You may wish to change the throws slightly to provide the D 4. Drill two holes (7/32" or size to fit your fuel tubing) smoothness or quickness that you prefer.

  • Page 30: Install Wing Strut Straps

    D 2. Secure the battery to the fuselage under the fuel on all sides (and front) with latex foam rubber. Leave a few tank, just aft of F-2. The battery must be secure, but must be inches of extra fuel tubing in front of F-1 (you can cut off the surrounded by foam rubber to protect it from hard vibrations.

  • Page 31: Install Wheel Pants

    "dimple." NOTE: Make a RIGHT and a LEFT therefore, if you will be flying your Super Decathlon 40 wheel pant! from a grass and/or rough field, we recommend that you do not install the wheel pants.

  • Page 32: Fit Cowl

    D 10. Insert an 8-32 x 1-1/2" socket head cap screw FIT COWL through one of your wheels (If the hole is too small, drill the wheel hub with an 11/64" drill bit). Slide on one #8 flat washer and screw on two #8 hex nuts. Tighten the two nuts against each other to lock, providing just enough space for the wheel to turn freely.

  • Page 33: Finishing

    FINISHING ADDITIONAL FUELPROOFING If you have not already done so, make sure the entire engine compartment is completely fuelproof. Also fuelproof any wood that will not be covered and which may be exposed to glow fuel residue. Use epoxy thinned with alcohol, polyester finishing resin or fuelproof paint.

  • Page 34: Apply Decals And Trim

    NOTE: When covering the fin and stab, begin by applying 1/2" wide strips of covering in the comers between the fin and stab, and (on the bottom of the stab) between the stab and the fuse. sides. Next, cover the stab and fin with pre-cut pieces that have a straight edge to overlap (1/8"+ overlap) the strips you previously applied.

  • Page 35: Glue The Hinges

    D 5. If you are planning to enter your Super Decathlon 40 in scale competition and you need maximum scale realism, D 6. Put epoxy into the aileron hinge slots and the torque...

  • Page 36: Wing Seating

    disturbing for at least 24 hours. 5. Remove the tape, then NOTE: Do not glue the windshield in place until after remove the wing from the saddle (leaving the waxed you have covered your model. paper or plastic wrap in place). 6. Gently pull the waxed paper or plastic wrap away from the sealer.

  • Page 37: Install Side Windows

    the strut straps. Apply a generous amount of thin CA to the D 3. Thoroughly clean the covering material around the window areas with alcohol, to remove all traces of skin oils. strut ends and screw holes to harden the balsa and prevent Poke pinholes (1/8"...

  • Page 38: Final Hookups And Checks

    FIND A SAFE PLACE TO FLY first flights with your Super Decathlon 40. You may wish to change the throws slightly to provide the The best place to fly your R/C model is an AMA smoothness or quickness that you prefer.

  • Page 39: Ground Check The Model

    also have insurance to cover you in case of a flying accident. Get help from an expenenced pilot when learning to (The AMA address is listed on the front cover of this instruc- operate engines. tion book). Use safety glasses when starting or running engines. If a club and its flying site are not available, you need to find a large, grassy area at least 6 miles away from any other Do not run the engine in an area of loose gravel or sand;...

  • Page 40: Flying

    If you notice any "sluggishness" in RADIO CONTROL the way your Super Decathlon 40 handles, it is probably a result of not enough speed, in which case you should install a 1. I will have completed a successful radio equipment propeller with a larger diameter or increased pitch.

  • Page 41: Notes

    NOTES Date Purchased: Where Purchased: Date Assembly Started: Date Assembly Finished: Finished Ready To Fly Weight: 8 Digit Code on Box End: General Notes: PROCEDURE FOR CHECKING THE WING INCIDENCE (See Page 24) 1. Block up the fuselage until the stabilizer (or stab bed) is perfectly level (use a small bubble level).

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