Table of Contents
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Great Planes Model Manufacturing Co., Inc. guarantees this kit to be free of 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, he is
advised to immediately return this kit in new and unused condition to the place of purchase.
READ THROUGH THIS INSTRUCTION BOOK FIRST.
IT CONTAINS IMPORTANT INSTRUCTIONS AND
WARNINGS CONCERNING THE ASSEMBLY AND
USE OF THIS MODEL.
INSTRUCTION BOOK
WARRANTY
PO BOX 788
URBANA ILLINOIS 61801
Entire Contents © 1992, Hobbico Inc.
2173984970
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Table of Contents
Related Manuals for GREAT PLANES Ultra-Sport 1000
Summary of Contents for GREAT PLANES Ultra-Sport 1000
- Page 1 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.
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Page 2: Table Of Contents
TABLE OF CONTENTS INTRODUCTION.......3 Install Turtle Deck......38 Precautions ........3 Assemble Nose Section ....40 Abbreviations........4 FINAL ASSEMBLY ......42 English/Metric Conversions.....4 Sand Fuselage .......42 Types of Wood........4 Install Wing Fillets ......43 Decisions You Must Make ....5 Shape Fin Fairings ......44 Other Items Required .......6 Mount Stabilizer and Fin....45 Supplies and Tools Needed....6 Install Servos, Horns &... -
Page 3: Introduction
If any parts are missing, broken or defective, or if you have the Ultra-Sport 1000 is easy to build and flies great, any questions about building or flying this we must discourage you from selecting this kit as... -
Page 4: Abbreviations
slightly from the photos In those instances you should assume the plans and written instructions COMMON ABBREVIATIONS USED IN THIS are correct Also you may notice a slight difference BOOK AND ON THE PLANS: in length between some of the longer parts and the plans This is normal and is caused by the plans Elev = Elevator... -
Page 5: Decisions You Must Make
J-TEC "JT-3000S" muffler which was custom made as a result of this project (it is pictured in an Ultra-Sport 1000 on the cover of the April, 1992 issue of R/C Modeler magazine) Both mufflers work well, but they are very different styles (See the photos on page 43) -
Page 6: Other Items Required
OTHER ITEMS REQUIRED SUPPLIES AND TOOLS NEEDED Four-channel radio with 6 servos (additional channel • 3 oz. Thin Bullet CA Adhesive and retract servo required if retracts are being used). An 800 to 1200 mAh receiver battery is • 3 oz. Medium or Thick Bullet CA Adhesive recommended (IMAA requires 1000 mAh) •... -
Page 7: Die Patterns
DIE PATTERNS Use This Drawing To Identify Die-Cut Parts... -
Page 8: Get Ready To Build
9" stick, cut the rudder bottom, and glue on the 1/4" x GET READY TO BUILD 1/4" x 3-1/2" balsa rudder top Cut two gussets from the remaining 1/4" x 1" balsa for the inside corners of D 1. Unroll the plan sheets Re-roll them inside out the rudder Working right on the plan, pin these parts to make them lie flat... -
Page 9: Fin
BUILD THE FIN NOTE: You will construct the fin framework and add the 1/16" balsa sheeting, then, you will add the 3/8" balsa leading edge and fin top. D 1. Cut the remaining 1/4" x 3/4" balsa stick to make the fin trailing edge. -
Page 10: Elevators
"ribs" (trussing). D 3. Carefully draw a centerline all around the edges D 12. If you are building your Ultra-Sport 1000 as a of the elevators (this will help to maintain symmetry "taildragger," check the plans and mark the location of when sanding). -
Page 11: Temporarily Install Hinges
between the stab sheeting and the stab D 4 Using a sanding block and coarse (50 or 80-grit) framework, especially in the center, therefore, we sandpaper, sand both sides of the elevators to a taper recommend using 30-minute epoxy when you apply as shown on the plans. -
Page 12: Wing Assembly
D (2) WBNT170 3/16" wire Main LG Struts CAUTION!!!: You must use extreme care when (PARTS NEEDED FOR OPTIONAL RETRACTABLE cutting hinge slots with an X-acto knife, to avoid LANDING GEAR) cutting yourself! If the balsa part breaks while D (2) US10W16 1/4"x1-5/16"x3-5/16" Ply Rear Mtng. Plate you are pushing on the knife, the blade could go D (2) US10W17 1/4"x3-5/16"... -
Page 13: Ribs
DOUBLERS (Fixed Landing Gear D 2 Sand one end of each of the medium and short TAILDRAGGER) spars to a 2-1/2" taper as shown in the "Wing Spar (Skip this section of you will be installing retracts) Detail" on the plan D 3. -
Page 14: Le And Te
LEADING & TRAILING EDGES The doubler for rib W-3 is marked for a long, narrow notch Extend the lines of this notch to the The shaped and notched wing leading edges edge of the doubler, and cut out this notch (LE) and trailing edges (TE) are fastened together by thin strips of balsa Separate them by cutting with an X-acto knife, as shown in the following sketch. - Page 15 space is limited, you may cut the left and right wing with the aft edge of the TE (see sketch below) half drawings apart may cover the top edge of the Jig with a strip of waxed paper or plastic wrap to avoid gluing it to the TE NOTE: Follow steps 2 through 45 to build the RIGHT wing panel, then repeat these steps to build the LEFT wing panel.
- Page 16 D D 11. Lightly sand the tops of the ribs to blend with the notched trailing edge; then glue one of the 3/32" x 2" x 39-3/8" balsa trailing edge sheets in place. NOTE: The edge of the TE sheet may not be exactly straight, but just position the sheet so it slightly This photo is not 100% accurate.
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Page 17: Le Sheeting
Check all glue joints, adding glue as necessary. NOTE: In the Ultra-Sport 1000 prototype we used B&D mechanical retracts, and you will see them in the D D 18. Using a razor saw and a sanding block, photographs You may use whatever type of retracts... - Page 18 NOTE: Install a wheel on the strut and check out how much force it takes to raise the wheel If you are using standard (heavy) wheels, it may be necessary to increase the tension on the retract assist spring you are using lighter wheels, such as Sullivan "Skylite" wheels, the stock spring tension may be adequate D D 29 Install the retract mechanism (with the gear...
- Page 19 the TE sheeting, and it should extend about 1/8" past IMPORTANT NOTE: To insure a straight wing, the ribs on each side to simulate cap strips Cut a you must pin or weight the TE securely down on hole in this sheeting over the servo rails just big the TE jig while the bottom sheeting is glued in enough for the servo to pass through, then mount the place!
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Page 20: Finish Installing Retracts
drilling straight down through the aileron (not perpendicular to the top or bottom surfaces) Harden the balsa in the area of the control horns (on both sides of the aileron) by poking several small holes with a pin, then applying thin CA glue Sand smooth. -
Page 21: Join Wing Panels
D 1. Place the two wing panels together on a flat surface and block up both wing tips 1-1/2". The blocks should be located at the W-13 ribs. Sand the root end of the wing panels until they fit together properly at that angle. -
Page 22: Sand "Flats" On Le And Te
D 9. Sand the wing joint smooth all around. Using 30-minute epoxy, securely glue the dihedral brace to the back of the spars Observe (in the photograph) how two small balsa wedges were used to hold the dihedral brace against the spars with slight pressure Wipe off excess glue that may have D 10 Now turn the wing right side up and cut a 1/2"... -
Page 23: Install Wing Dowels
Make location marks for the fiberglass D 8 After the glue has set, trim the excess cloth at reinforcement cloth, 2" each way from the wing the trailing edge with a sharp X-acto knife followed by centerline. Cut the 4" x 36" strip of glass cloth in half, a sanding block. -
Page 24: Install Wing Bolt Plate
Slightly round (or chamfer) the ends of the dowels that INSTALL RETRACT SERVO will protrude out of the LE (Skip this section if you are using fixed gear) Trial fit the dowels into the dowel holes should be able to probe around and find the dowel holes in the dihedral brace Now trial fit the dowel plate over the dowels If the dowels fit too tightly, you... -
Page 25: Fuselage Assembly
FUSELAGE ASSEMBLY NOTE: For ease of working with these big plans, you may cut out the fuselage top and side views and work with them separately. D 3 Carefully position the die-cut 3/16" balsa lower PREPARE FUSE SIDES front fuse side so the vertical rear edge lines up with PARTS NEEDED the front of the wing saddle opening on the plan (the D (2) US10F01... - Page 26 sufficient glue so it flows under the doubler to produce a strong bond D 11 From the 3/8" x 30" balsa triangle, cut pieces to fit between the tail wedge and the rear of F-4, along the bottom inside of both fuse sides. Glue in place. D 8.
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Page 27: Prepare The Firewall
correct size for the "A" firewall location (see Engine Application Table). If your engine requires the "B" or "C" firewall, it is necessary to cut the firewall down to the proper size Drawings for all three firewalls are shown on the fuse plan. Use these drawings to determine how much to cut NOTE: The top and... -
Page 28: Prepare Stab Base
D 5. Permanently attach the nose gear bearings (if D 3. Temporarily assemble the stab base, the stab applicable) to the back of the firewall with the 4-40 x anchor block and the die-cut 1/8" ply former F-6 onto 3/4" machine screws, cut off the excess bolt length one of the fuse sides. -
Page 29: Prepare Formers
the stab anchor block, and between the anchor block D (1) US10F21 1/4"x1/2"x2-11/32" Balsa Aft Cross Brace and the tail wedge (notice how the triangles are D (1) US10F07 1/2"x30" Balsa Triangle Stock sanded to a taper near the aft end). Glue the triangles D (1) US10F10 3/8"x15"... - Page 30 D 8. Place the above assembly upside down on the waxed paper covered plan, and align the aft portion of the fuse with the plan. Begin pulling the fuse sides together, and pin the sides to the board every few inches as you work forward.
- Page 31 sanding as necessary for a good fit. Glue the hold- down plate in place securely, using 30-minute epoxy. Then cut pieces of 3/8" hard balsa triangle and glue them in place above and below* the hold-down plate. Sand the triangles flush with the wing saddle. *You may wait to install the triangles under the hold-down plate until after you are able to turn the fuse right side D 17.
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Page 32: Install Servos, Guide Tubes
INSTALL SERVOS AND PUSHROD GUIDE TUBES PARTS NEEDED: D (2) US1 0F09 1/4" x 1/2" x 4-3/8" Ply Servo Rails D (4) PLTB002 36" Plastic Outer Pushrod Guide Tube D (1) NYLON69 Nylon Nosegear Steering Arm D (1) SCRW007 6-32 x 1/4" Socket Head Cap Screw D (2) WIRES17 34"... -
Page 33: Mount The Wing To The Fuse
strut from slipping under high stress Leave the steering arm and pushrod in place D 12 With the engine resting on the mount, plan the throttle pushrod routing The pushrod should be located as close as possible to the fuse side (to allow room for the fuel tank), and the guide tube should not have any tight bends Drill a 3/16"... - Page 34 D 3 With the fuselage upside down on a flat surface, trial fit the wing into the wing saddle You may have to enlarge the holes in F-2 in one direction or another (using a round file), and you will probably have to sand the wing saddle a bit to allow the wing to seat properly.
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Page 35: Fit Fuel Tank, Fuelproofing
FIT FUEL TANK and FUELPROOF TANK and fill lines The location of these holes will depend COMPARTMENT somewhat upon the type of engine you are using etc It is OK to drill the holes in the upper left and upper right corners, but we prefer drilling both holes in the upper right corner (as viewed from the rear) for easier access The holes must be located at least 5/8"... - Page 36 D 2. Glue together the two halves of the 3/4" balsa chin block. Sand the glue joints smooth with your T- bar. D 6. If you're using trike gear, use a long 3/16" drill bit to drill down through the nose gear bearings and out through the chin block.
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Page 37: Assemble Belly Fairing
ASSEMBLE WING BELLY FAIRING PARTS NEEDED: D (2) US1 0W22 1/8" Die-cut Balsa Belly Fairing Sides D (1) US10F39 1/8" Die-cut Balsa Belly Fairing Formers D (2) US10W18 1/2" x 1-1/2" x 1-1/2" Balsa Fairing locks D (1) US 10W33 1 /8" x 3" x 24" Balsa Belly Fairing Sheeting D (1) US10W19 1/4"... -
Page 38: Install Turtle Deck
between the belly fairing sides and the bottom wing sheeting. INSTALL TURTLE DECK PARTS NEEDED: D 5. Add 1/4" balsa triangle along the edges of the D (1) US10F27 1/8" Die-cut Ply Formers F-3A. F-4A and belly fairing sides to provide extra material for F-5A rounding the corners. - Page 39 D 3. Glue the 1/4" x 1/4" x 31" balsa top stringers and the 1/4" x 1/4" x 21" balsa side stringers to the formers HINT: If F-3A is slightly warped, you may D 7 Glue the bottom edge of the sheeting to the top straighten it during this step by twisting it straight while of the fuse sides gluing the stringers...
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Page 40: Assemble Nose Section
NOTE: From now on, when working on the fuselage upside down, you should always support the fuselage in a protective stand, such as a Robart "Super Stand" to avoid dents and nicks. ASSEMBLE THE NOSE SECTION D 11 Using a long T-bar or sanding block with 80-grit sandpaper, sand the sheeting and stringers flush with PARTS NEEDED the top edges of the formers. - Page 41 D 6. Now center your spinner backplate over the spinner ring, and tack glue it to the 3/32" balsa spacers. D 9. Lay the top front block in place on top of the fuselage. The aft end of the block should be in the position shown on the plans (measure forward from F- 3A).
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Page 42: Final Assembly
D 12 Remove the prop nut and propeller Pop the spinner backplate loose with a screwdriver and remove the spacers Remove the engine and mount in preparation for the next step, but mark the outline of the engine mount on F-1 with a pencil Photo shows SuperTigre 2500 engine with Supertigre muffler installed D 13. -
Page 43: Install Wing Fillets
with new #50 or #80-grit sandpaper for rough shaping After the rough sanding has been completed, The very coarse sandpaper is used to achieve the temporarily re-mount your engine and slide on the basic shapes Then use progressively finer grades of spinner backplate You'll probably have to sand down sandpaper for a smooth finish. -
Page 44: Shape Fin Fairings
nice fillets behind the little formers using lightweight filler. D 5. If you used lightweight filler to form the fillet, after sanding smooth you may spread a coat of thin D 3 You may build the fillet on top of the fillet base in CA over the surface of the filler, then give it a final one of the following ways. -
Page 45: Mount Stabilizer And Fin
D 3. Apply a few strips of masking tape to the turtle D 5. Lay the stab in position on the stab saddle with the center point lined up with the tail end of the deck for protection, then carve and sand the above assembly to blend smoothly with the fuse sides and fuselage. -
Page 46: Install Servos, Horns & Pushrods
D 9 Carefully align the fin on the stab The fin must INSTALL SERVOS, HORNS AND PUSHRODS be positioned perpendicular to the stab and must D 1. Re-mount the aileron servos in the wing, and line up with the fuselage centerline EXACTLY! mount the nylon aileron horns. -
Page 47: Control Surface Throws
NOTE: While installing the pushrods, position the **The Ultra-Sport 1000 has a slight tendency to pitch above plastic tube spacers so they always stay inside down when full high rate rudder is applied If you have the pushrod guide tubes... -
Page 48: Finishing
curved "Lexan Scissors" (available from your hobby FINISHING shop) is a very handy tool for trimming the canopy NOTE: The trim line on the canopy is approximate. ADDITIONAL FUELPROOFING Your canopy trim will vary, depending on how you sanded the fuselage It may be necessary to do some If you have not already done so, make sure additional sanding of the fuse near the front of the the entire engine compartment is completely fuelproof. -
Page 49: Covering
COVERING rounded tip, and follow the iron with a damp cloth, pressing the covering down. NOTE: Top Flite Super MonoKote was used to GLUE THE HINGES cover and trim the prototype models of the Ultra- Sport 1000, and that is the recommended covering 1 Lay the rudder, elevators and ailerons on the plans for this model. -
Page 50: Glue Canopy In Place
To avoid sanding more than you want, it is helpful to RE-INSTALL ENGINE & RADIO first apply strips of vinyl tape (such as Great Planes "E-Z Mask") on the inside of the canopy, 1/8" in from Re-install the engine, propeller battery,... -
Page 51: Final Hookups And Checks
gluing strips of lead into the engine compartment 3. Check for wing twist as follows: under the engine Tail weight may be added by using NOTE: Even if you have built your wing on a perfectly "stick-on" lead weights*, and, later, if the balance proves to be OK you can open the fuse bottom and flat surface and used utmost care, it is possible that your wing may have a twist due to uneven shrinking of... -
Page 52: Range Check
all the control surfaces do what they are supposed to. The engine operation must also be checked and the •Use a low throttle setting when starting the engine. engine "broken in" on the ground by running the engine for at least two tanks of fuel Follow the •Make all engine adjustments from behind the rotating propeller engine manufacturer's recommendations for... -
Page 53: Landing
) an electronic t h i n g (bad servo resolution or dead-band in the radio system), or C G (aft Center of SEE THE FULL LINE OF GREAT PLANES Gravity will make the plane wander a bit) The last possibility will... - Page 54 Do the bank in both directions j u s t to make sure that you arc getting an accurate Reprinted in part by Great Planes Model Manufacturing Company, reading of the l o n g i t u d i n a l balance courtesy ot Scale R/C Modeler magazine.
- Page 55 TRIM FEATURE MANEUVERS OBSERVATIONS CORRECTIONS CONTROL Fly general circles and Try for hands off straight and Readjust linkages so that CENTERING random maneuvers level flight Tx trims are centered CONTROL Random maneuvers. A Too sensitive jerky If A change linkages to THROWS controls reduce throws...
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Page 56: Ama Safety Code
AMA SAFETY CODE IMAA SAFETY GUIDELINES As of September 15, 1989 Read and abide by the following Academy of Model (Portions reprinted as follows) Aeronautics Official Safety Code. For the purpose of the following IMAA Safety Guidelines, the term "Giant Scale" refers to a radio GENERAL controlled model aircraft, either scale or non-scale, I will not fly my model aircraft in competition or... - Page 58 • The kit quality and sparkling performance of the • Impressive Super Sportster 90/120 gives you large- Ultra-Sport 1000 in .40- and .60-sized models. scale dimensions without sacrificing aerobatic performance. • Even if you're a veteran pilot, you'll be surprised at how much "better"...
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Page 59: 2-View Drawing
2-View Drawing Use This For Planning Your Trim Scheme...