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Enhancing the Homebuilt Experience

1. Aircraft Models Enhancing the Homebuilt Experience Radio Control Scale Model Glasair SII Glasair II Scale 1 3 5 28 Full Size Wingspan 80 2032 mm Wing Area 1024 in 66 1 dm Flying Weight 12 lbs 5 04 kg Wing Loading 27 oz ft Length 70 1778 mm Radio 5 Channels with 7 servos Engines 1 08 1 2 cu in 2 Cycle 1 20 1 4 cu in 4 Cycle WARRANTY Experimental Aircraft Models LLC EAM guarantees this kit to be free from defects in material and workmanship The warranty does not cover individual parts damaged by modification or abuse In no case will EAM s responsibility or liability exceed the original purchase price of the kit EAM reserves the right to change or modify this warranty at any time EAM assumes or accepts no liability for the manner in which this model aircraft is used by the user in any condition of assembly By the act of purchasing this kit the purchaser and any subsequent user accepts full responsibility and all resulting liability If the purchaser is not willing to accept the above liability associated with the use of this model aircraft the purchaser is advised to return this kit immediately to the source from where it was obtained Please read this manual thoroughly before starting assembly It includes critical assembly instructions and warnings in regards to the safe and enjoyable use of this scale aircraft model Experimental Aircraft Models LLC 1224 A
2. Heavy Duty Servo Lead Extensions 2 150mm 6 for flaps with Futaba Plug recommended 1 Y Harness Heavy Duty for ailerons with JR Plug recommended 1 Reversing Y Harness Heavy Duty for flaps with Futaba Plug recommended 4 40 or 3mm Pushrod Hardware optional required for IMAA events Remote glow plug lighter optional Fuel Filler valve optional 1 or 2 Pilot Busts optional Small jar fuel proof paint for under the cowl amp touch ups optional Lighting Kit optional available from Kondor Model Products OOOOOOU OO OOOOO On the Y harnesses if you get one of them with the JR plug and the other with a Futaba plug then they can be mated to the same style either JR or Futaba connector on the Servo Extension end to prevent cross wiring If both plugs are the same style then you will have to mark each lead with a flag identifying its purpose Page 5 Experi va Aircraft Models ASSEMBLY MANUAL Glasair SII Ill WING ASSEMBLY The flaps are already hinged and ready to go however the hinge points in the ailerons must be installed Next we ll install the servos on their mounts install the control horns and linkages wiring harnesses and finally install the servos in the wing Aileron Hinges A go slow approach works best here The best way to align the hinge points is to epoxy them into just the aileron then after the epoxy cures epoxy the hinges to the other s
3. Covering Removed O 10 Install the horizontal stab using 30 minute epoxy and CA Begin by applying a wet but not too globby coating of epoxy inside the top of fuselage the top block that contacts the stab Next apply a wet coat to the top of the stab not the bottom Carefully slip the stab to just before the epoxied area Lay a bead of epoxy on the previously wetted stab next to where it is ready to enter the fuselage Slide the stab in that bead of epoxy should spread itself out along the way When you get the stab all the way in place the area where you cut the covering K should guide you to aligning the stab but va measure it anyway to confirm alignment to the wing tube Use some paper towels soaked with alchohol or acetone to clean up an excess epoxy on the surface of the stab Flip the fuselage over again making sure the stab is aligned wet the bottom stab to fuselage joint with medium CA This will lock the stab into position and hold it while the epoxy cures Page 21 wnn Aircraft Models ASSEMBLY MANUAL Glasair SII Ill Coat the bottom of the fin with epoxy and slip the fin into position This should pull the fin down into its slot Back on top use any extra epoxy to fill in any remaining gaps around the stab or between the fin and the fuselage Clean up the excess epoxy again then let it sit until the epoxy cures out Stabilizer and Fin Installed O 11 Back in step 1 we epoxied the hinge points to the
4. different iil Install the engine mounts to the firewall using the supplied 4mm x 30mm bolts Install these loosely enough to allow adjustment in width to fit the intended engine Slip the engine into the mounts and hold in place with a rubberband Align a straight edge with the front of the drive washer Slide the engine fore or aft on the mount until the distance from the firewall to the drive washer is 1 5 mm to 3mm 4 s greater than the cowl length measured in Step 3 For this example the cowl length was measured in Step 3 was 5 75 146 mm so the target dimension firewall to drive washer is 5 81 5 87 147 5 149 mm Firewall to Drive Washer Target Dimension and Actual 10 When the engine position has been set spot mark the ees of the eng mounting holes on the mounts The engine mount can be drilled either in place or the mounts can be removed and set up in a Drill Press Vise for drilling Drill the mounts for the 3mm x 30 mm or 6 32 x 1 25 engine mounting bolts OPTIONAL If you have the proper tools drill and tap the mount for the 3mm or 6 32 engine mounting bolts In any case 3mm or 6 32 lock nuts must be used to lock down the engine to the mounts Engine Mount Drilled O 11 Temporarily mount the engine in preparation for Engine Mounted O 12 Slide the cowl over the engine Install the spinner cowl fitting Omit the muffler for now backplate and use a spacer or a pro
5. head bolts that secure the wheelpant to the gear leg then lock down the axle bolt We drilled an access hole through the wheelpant to the outside just large enough for a screwdriver to make it easier to install the screw for the main wheel Main Wheels amp Wheelpants Installed L 9 The Main Gear mounts are located under the covering just aft of the lower wing fairing Cut away the covering to expose the mounts and seal the edges of the covering Main Gear Installed O RADIO SET UP 1 The dual outputs on the elevator work best when the pushrod runs straight down the center of the fe Gag steering Pull Bue ables Foner fuselage Some compromise versus perfection i must be tolerated but can be minimized by mounting the elevator servo in the center bay of the servo tray The throttle servo go in on the side that gives best access to the throttle arm in this case the throttle servo went into the starboard side location to align with the throttle arm eile the port servo bay for the Rudder Nosegear servo Drill pilot holes and mount the Servos Fuselage Servos Installed O 2 The Rudder Pushrod to the tail should go to the Port side of the servo arm Center the servo and adjust the pushrod to neutralize the rudder Rudder Pushrod Installed O Page 26 a Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 3 The Nose Gear Pull Pull cable installation starts at the end arm sh Ail first slipping one of the
6. a permanent marker to identify which tube is which it WILL help you later Fuel Tank Assembled LJ 6 Slip the fuel tank into the tank compartment ane ee it nonwale until the neck sticks through the hole in the firewall p p99h 3 Temporarily install the engine ia CK mounts using the supplied 4mm x 30mm bolts With the side mounted engine the lower ae inundi mount croses the fuel tank neck ess opening and will likely interfere BEES with the fuel tank tube The simple way out is to push the ines TUF fuel tank back far enough to clear the mount However if you want to keep the tank as far forward as possible thus minimizing the fuel draw you will have to grind a clearance notch into the lower mount Engine Mount Cleared O 7 Remove the tank With the engine mounts installed note that the two lower bolts will interfere with and potentially could puncture the fuel tank To prevent that Be a scrap wood spacer that keeps the tank from moving forward and contacting the bolts The spacer shown is a piece of 3 8 square balsa Tank Shim Installed O Page 13 Expe Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 8 Measured Cowl Length 9 Slide the cowl into position all the way back against the fuselage Measure the distance from the Engine mounting firewall to the nose ring of the cowl in this example the distance was measured aui as 5 75 146 mm your dimension might be slightly
7. details about the production of this model We control the entire process of the model construction starting with the direct import of balsa logs from Ecuador to hand carving the fiberglass plugs and lay up of the fiberglass components The canopy molds are also hand carved and the vacuum forming is all done in house You get to make similar choices as the Glasair homebuilder type and size of engine fixed gear or retracts as well as many other touches that customizes their personal aircraft or your model In addition our Glasair SII III model will also accommodate a lighting kit in the wing tip A final point Because the model is so special and the volumes by model standards so low we need your help We have tried our absolute best to get everything right the first time If there is something during the construction and flying of the model that you feel could be done more easily or better we d like to know This is how it s done in the full size experimental aircraft world and we want to be sure that the same spirit is carried on in smaller scale Full scale Glasair builders are continually finding ways to improve the full size aircraft and there is no reason why modelers should not have the same ability to contribute to a better product We sincerely appreciate your vote of confidence in purchasing our rendition of the Glasair SII III and truly wish you the best of enjoyment Please feel free to e mail us with kit comments
8. dorsal Use medium CA or epoxy to install the dorsal fin Dorsal Fin Installed O 13 Next install the Elevator Pushrod The easiest way to do this is to start by installing a plastic tube in each m of the UPPER fuselage slots under the stabilizer Slide these forward until they reach the radio bay Slip one end of DV4 A cay yi AN Page 22 rwn Aircraft Models ASSEMBLY MANUAL Glasair SII Ill the Y pushrod into each of the plastic tubes then push the rod into the fuselage the plastic tubes will guide the ends of the Y out the slots in the fuselage Elevator Pushrod Installed O 14 Next install the Rudder Pushrod You can use the plastic tube as a guide as you did with the elevator pushrod but frankly the rudder pushrod is simple enough to just reach into the fuselage and poke around until you find the lower pushrod exit on the starboard side of the fuselage Rudder Pushrod Installed O 15 Next install the control horns For the rudder start by installing the horn on the clevis on the rudder pushrod This will align it at the correct height Next slide the base of the horn on the fore and aft on the rudder until the pushrod holes align with the hinge line Put a pin in one hole to locate it while you drill the other Then put a screw into the hole you just drill remove the pin and drill the second hole Rudder Horn Installed O 16 When using a double ended pushrod it is imperative that th
9. from our web site at www rchomebuilts com or call us toll free 888 968 7251 Andrew Kondor Managing Director Experimental Aircraft Models LLC Page 2 Expe ell Aircraft Models ASSEMBLY MANUAL Glasair SII Ill GENERAL ASSEMBLY NOTES Before you Begin Congratulations on your selection of the Glasair for your aero modeling project This manual is written for modelers with some prior RC model building experience and tools There is always a question of how much detail should the manual include If something is unclear then please contact us for help Similarly your Glasair is supplied with quality hardware but some additional parts listed below are needed Again if you need some help in selecting what you need contact us One of the first things to determine is exactly WHAT version of the Glasair are you going to build Just as the homebuilder customizes MHH their personal aircraft your Experimental Aircraft Models kit enables you to choose between the Fixed Gear or Retract equipped Glasairs O The Glasair S Il or Super Il line offers the RG Retractable Gear the FT fixed tricycle gear There is also the TD Tail Dragger variant but that is beyond the realm of your new EAM kit unless you want to customize O All Glasair Ill s have retractable gear Thus if you build your model with a fixed trike gear it will be a Glasair SII FT If you build it with the optional Robart retracts it will be eith
10. gear is used If you are using the fixed gear the clearance notch is not required in fact it can be come a leak zone for air and fuel from the cowl to enter the inside of the fuselage Therefore it is recommended that you either cover or fill this clearance notch Shown are a couple pieces of scrap balsa installed with silcone seal thus removable if the retractable gear is ever used Retractable Wheel Clearance Notch Sealed O 6 Install the Nose gear pivot block with its wood spacer onto the firewall using the 3mm bolts provided Nose Gear Block Installed O 7 The main gear assembly begins with installing the wheels and wheel pants onto the main gear Sort out the two 4mm x 40mm shoulder bolts 6 washers and 4 lock nuts as well as the main landing gear legs wheels and wheel pants Examine the main gear legs note that they are not symmetrical Install them with the gear swept forward that is with the straight side of the gear forward and the tapered side in back Main Gear Parts Identified L 8 Slip the 4mm axle bolt through the wheel and install one of the locking nuts then two of the washers Slip this into the wheelpant and snug up the nut on the screw just enough to keep the wheel spinning freely but not rattling from side to side slip the bolt through the main landing gear leg and loosely install the remaining lock nut Install the two 3mm washer Page 25 a Aircraft Models ASSEMBLY MANUAL Glasair SII Ill
11. into play Use tin snips to cut from the back of the cowl to the exhaust tube holes this gets you close Reinstall the muffler slip the cowl into place and start filing sanding or grinding the cowl opening to fit the muffler A Dremel grinding tool with a sanding drum used with care and patience will help you finish the job quickly Strive for a minimum 3 mm 1 8 clearance between the exhaust tube and the cowl In an effort to maintain a cleaner line note that the sides of the cut follow the sides of the lower cowl Scoop Cowl Fitted Over Muffler O Page 15 Expe va Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 15 By the way if you choose an inverted installation most of the steps are pretty much the same EXCEPT the fuel tank neck will not interfere with the engine mount The throttle pushrod location will be vastly different and you WILL have to cut a hole where the engine cylinder juts through the cowl You may also have to cut holes to clear the muffler you choose We still think the side mount is a better idea Under Cowl Installation Detailing The Glasair cowl makes for a super clean installation but access is blocked for simple things like fuel filling and glow plug access To be Sure it is possible to simply cut access holes for the glow plug and it is possible to route some of the fuel tubing outside the cowl but that can detract from the clean appearance Thus we will install these feature
12. movable surfaces Now its time to finish the job If you have not done so already check out EVERY HINGE and make sure it moves freely and is free of excess epoxy Remember the tape markers we put on the elevators match them all up Pre install and make sure every thing fits well in preparation for the final installation Mix a batch of 30 minute epoxy Using a toothpick wet out and put a drop on each hinge point hole Carefully install each control surface Use 1 32 balsa or thin cardboard shims to assure a uniform and close hinge gap on each surface Allow to cure preferably overnight When cured wiggle each control surface and inspect EVERY hinge for signs of globs of epoxy that could be interfering with free motion of the control surface Elevators amp Rudder Installed L 12 The last tail piece to install is the dorsal fin The Glasair has a relatively short tail the extra side area atforded by the dorsal improves directional stability do not leave it in the box Take some care to properly align this piece For alignment on the centerline of the fuselage use the location of the top most fuselage stringer which is visible at the aft hatch bulkhead Another good reference for centerline is the overlapping seam in the covering at the top of the fuselage As always remove a strip of covering from the top fuselage and the base of the fin leading edge Also make sure to remove any covering overlapping the gluing surfaces of the
13. off the wire O Slip the wire into the fairing part way O Then slip a collar onto the wire O Then slip the wheel onto the wire O Then slip the second collar over the wire DO NOT tighten anything yet 2 Center the wheel in the fairing and lock down the collars to hold it in position Allow enough clearance for the wheel to spin freely Shim 5mm Spinner N LS LS 3 Fiton of the metal brackets over the wire and onto the fairing near the top Drill the two 1 5mm 16 holes into the fairing where the bracket goes and install the bracket screws Repeat for the second bracket to be located somewhere midway along the wire and fairing juncture 4 Slip the nose gear through the steering arm note that a flat has been ground into the wire for the steering arm set screw Slip the wire through the Nose Gear Block Page 24 Expe Aircraft Models ASSEMBLY MANUAL Glasair SII Ill and the wire collar note that there is another flat ground into the wire where the top collar is installed This may or may not be the case for your Glasair but for the model assembled for this manual we used the smallest 5mm spacer supplied with the spinner as a filler piece to help reduce excess play in this assembly Lock down all the set screws Nose Gear Assembled amp Ready for Installation LO 5 The Glasair is prepped for retracts including a notch cut into the firewall for clearance to the nose wheel when the retractable
14. tab centered Nose Gear Pull Pull Cables Installed O 4 The elevator pushrod should be installed to the Nose Gear Pushrod Installed O servo arm and adjusted so the elevator is neutral with the servo arm centered 5 The throttle pushrod location depends on your engine and whether you choose to mount the engine side mount or inverted In our model we also tried to keep the pushrod close to the fuselage side With the engine installed determine where the throttle pushrod should pass through the firewall and drill a hole Use that a guide to drill through the second bulkhead In our model we also drilled a hole through the third bulkhead just ahead of the servos Page 27 Experi Aircraft Models ASSEMBLY MANUAL Glasair SII Ill DODA l Re A osia aS DUN A Wi nae DA SAT e S s DR on throttle J y gt 3 Sa p e k 8 Lent 1 Position pushrod jii lt lt Plastic tube using long drill em pushrod Throttle Pushrod Installed O 6 The Glasair kit provides two alternative places on the forward starboard side of the fuselage to mount the radio switch The smaller opening is designed if you plan on using the normal switch and separate charging harness of the normal switch the larger opening is for a combination switch with charging jack as shown in the picture set below This particular switch used was actually slightly smaller than the pre cut hole so the first picture shows how to fi
15. thin piece of balsa or thin cardboard as spacers to set the gap consistently Use some tape on the aileron to hold the position and then try to set the wing up on its trailing edge while the epoxy cures That way any excess epoxy pushed inside the wing should flow back and help lock the hinge point in place Port AileronO Starboard AileronU Wing Servos 1 Servo Covers Sorted amp Prepped 10 20 30 40 2 Servos amp Covers Clamped 10 20 30 40 3 Servo Cover 10 20 30 40 Locate the four servo covers and eight mounting x blocks Note that two of the servo covers have the pushrod slot offset to one direction and the other two to the other direction Rough up the inside surface of the servo cover with some sandpaper to promote beiter adhesion of the servo mounting blocks Position the servo by centering the servo output arm in the slot then use a spring clamp to hold it in position OPTIONAL put a dab of silicone seal on the servo before clamping the servo down it will help retain the servo but still allow the servos to be popped off if needed for service With the servos clamped in position epoxy the mounting blocks in close under the servo lugs After the epoxy cures drill a 1 5mm 46 hole through each grommet and screw the servos to the mounting blocks 4 Next step will be to install the servo wire extensions Each Flap servo needs a 150mm 6 extension each aileron a 450mm 18 extensi
16. ck from the field on what works for them one such item had to do with making it easier to install the cowl The Glasair cowl is very large and strong but it is also rather flexible and it can be a chore getting it aligned all the way around the perimeter so it will push Ramps Added 4 places back over the firewall bulkhead The suggestion made and shown here is to ADD some ramps fabricated out of scrap wood at the 4 corners of the firewall that will help guide the cowl into position These are OPTIONAL but we found that they help us align the cowl Corner Ramps Optional x 4 installed 4 Locate all the tank hardware The tank is supplied with a plastic clunk line suitable for use with gasoline fueled engines for normal 2 stroke glow you can use a more flexible silicone line possibly with a stiffener tube to prevent the line from folding back on itself Corner Ramps Optional x 4 installed 5 Bend two of the tubes into a fairly large radius right angle bend When installed one of the tubes overflow capped during flight will go the top of the tank the other muffler pressure goes to the bottom The engine fuel feed clunk line should be just about 10mm g short of the back of the tank Install the tubes and Page 12 Expe Aircraft Models ASSEMBLY MANUAL Glasair SII Ill stopper align the tubes and carefully tighten the wrap and tighten the tie strap that retains the stopper on the tank When completed use
17. de up However it looks better if the covering seam is out of view Thus examine the stabilizer along the leading edge and determine where the covering Page 19 wian Aircraft Models ASSEMBLY MANUAL Glasair SII Ill overlap seam is along the leading edge Use the edge of that seam to determine the bottom of the stabilzer use a marker to write BOTTOM at the center of the stab on the bottom side Bottom of Stabilizer Identified and Marked O 5 Before removing the elevators from the stabilizer mark the elevators and the stabilizer on each side with either a 1 or 2 In the picture the mark is just barely visible near the leading edge of the horn balance Use a washable marker or write the numbers on a piece of tape FIRST then transfer to each surface Intent is to not lose track of which elevator is mated to which side of the stab After marking remove the elevators While you are at it remove the rudder from the fin Elevators Marked amp Removed O Rudder Removed LJ 6 Remove all the hinge points we will be installing them to JUST the movable surfaces first Check all of the hinge pockets and clean up any execss covering ot other obstrction using a modeling knife Epoxy the hinge points into just these surfaces After the epoxy cures check the hinges for free motion chip away any excess epoxy and set these aside until they are needed again Hinges Epoxied into both Elevators O To Rudder O 7 Next sequence is to align
18. e elevator horns be installed correctly and exactly opposite each other in order to assure that the elevators always move in complete unison Start by loosely taping the FRONT of the pushrod to the center of the servo mounting bar up front Better still use a small piece of plastic over the wire so the pushrod will still move Install an elevator horn on each clevis Use some clamps or tape to hold both elevators in the neutral position Position the horns an equal distance from the centerline of the fuselage i e offset from the edge of the elevator by i 12 16mm 2 to s from the edge of the elevator Use a pin in one of the horn mounting holes to hold its position on the elevator then drill Rudder Horn Installed O Align the horn and link with the servo arm align the horn as far forward as possible WITHOUT overhanging the beveled edge then drill a 2mm g4 hole for each control horn screw NOTE in order to prevent drilling through the control surface use a drill stop The middle picture shows a wheel collar affixed over the drill bit to assure that the hole is drilled just as deep as needed for the screw With the rear most screws you might want to cut off the excess screw length and file off the burr Page 23 a Aircraft Models ASSEMBLY MANUAL Glasair SII Ill LANDING GEAR INSTALLATION Fixed Trike Gear Set up 1 Locate the nose gear r fairing W wire wheel collars TT SEA TAKE the wheel and colors
19. er a Glasair Ill or a Glasair Super Page 3 rwn Aircraft Models ASSEMBLY MANUAL Glasair SII Ill Il RG For the complete lineage of the Glasair series see their website at www glasairaviation com No matter what you call it you have your hands on a slick model of a very impressive full size aircraft Please note that we use aircraft terminology in our instructions Specifically Port is to Pilot s left Starboard or Strbd is to Pilot s right Forward is to the front and Ajit is to the rear No matter how you may have the model turned Port is always the left side of the aircraft as the pilot sits in the cockpit facing forward A note about the covering Your Glasair is covered in Oracover commonly known as Ultracote in the U S This is a high quality material but through temperature changes during shipping the model may show wrinkles This is normal This symptom is also more visible in that the model is fully balsa sheeted The material can easily be tightened by the application of heat from a hair dryer heat gun or hot iron If using an iron a piece of lightweight cotton e g sheeting placed between the iron and the covering helps to even the heating Pressing lightly will transfer the heat to the covering shrinking the material Piercing a bubble with a pin and rubbing the hot area with a cloth further helps remove the wrinkles Oracover is a very slippery finish that that res
20. ese items not that WE have Page 4 Expe saint Aircraft Models ASSEMBLY MANUAL Glasair SII Ill ever done that Collect these items in a medium size plastic container or zip lock bags to keep them safe until used If you tag or mark them then you might even remember where they came from O The Glasair is supplied with METRIC hardware Most hardware sold in America is English Unfortunately some of the English and metric hardware are just close enough that they can be mixed usually with disastrous results Do not mix metric and English thread fasteners they WILL fail O The supplied elevator and rudder pushrod clevis are 2mm and adequate for the job at hand However the Glasair is IMAA legal and if you fly it at an IMAA event they will likely require that you have either 4 40 or 3mm size pushrod hardware The fixed gear Glasair requires a 5 or more channel radio system with 7 standard size servos We like using ball bearing servos for their durability Add retracts and you need a 6 channel and at least one more servo Technically the Glasair could be flown with a 4 channel radio with 5 servos with fixed gear and the flaps locked in the neutral position but where s the fun it that Additional components you may need from the hobby shop CA Adhesive Thin CA Adhesive Medium Epoxy 30 minute cure silicone Seal Adhesive Heavy Duty Servo Lead Extensions 2 450mm 18 for ailerons with JR Plug recommended
21. ffix the metal links to the wood dowels then secure the joint using heat shrink tubing or heavy duty sewing thread Elevator amp Rudder Pushrods AssembledU 2 The elevator and rudder pushrods need to be configured as shown in the picture to Rudder Pushrod Completed O 3 Follow along with the picture The two fit amp function properly The Rudder pushrod simply _ to be Paon 25 6 measured from pin to pin on the S clevis The pushrod shown also had some small Z bends to improve the fit there is no way to predict exactly what if any bends will re required just make sure the pushrod slides freely without en ad APROX Cian O t BITS pin interfering with the elevator rod final a of adjustments are made with the servo arm and rudder centered links at the output end of the elevator Fe 120mm 4 7 pushrod must be bent to form a Y as a shown The wire with clevis should overhang the end of the wood dowel by about 150mm 6 The rod ends need to be equally bent so that about 120mm from the end of the dowel they reach a width of 75mm 3 The ends of the rods need to be bent back to parellel maintaning the 75mm 3 dimension The overall length of the rod is about 645mm 25 4 pin to pin final adjustments are made with the servo m arm and elevators centered Rudder Pushrod Completed O 4 The Horizontal stabilzer is symetrical and technically can be installed with either si
22. he wing root so they do not inadvertently get pulled back inside the wing Port Aileron Servo Wiring Routed Through the Wing O Port Flap Servo Wiring Routed Through the Wing O Strod Aileron Servo Wiring Routed Through the Wing O Strbd Flap Servo Wiring Routed Through the Wing O 7 Assemble the clevis onto the aileron amp flap links and install each link onto a control horn Align the horn and link with the servo arm align the horn as far forward as possible WITHOUT overhanging the beveled edge then drill a 2mm 64 hole for each control horn screw NOTE in order to prevent drilling through the control surface use a drill stop The middle picture shows a wheel collar affixed over the drill bit to assure that the hole is drilled just as deep as needed for the screw 8 Install the horns With the rear most screws you might want to cut off the excess screw length and file off the burr it looks better than that extra screw point poking through on the top Port Flap HornU Starboard Flap HornU Port Aileron HornU Starboard Aileron HornU 9 Drill out servo output arms to 2 mm 64 to accept the wire pushrods Port Flap ServoL Starboard Flap ServoU Page 9 Expe va Aircraft Models ASSEMBLY MANUAL Glasair SII Ill Port Aileron Servo Strod Aileron Servo 10 Unless you are using a computer radio with the ability to reverse mix the flap servos you will need a reversing Y Harness for the flap servos Frank
23. ing able to easier over control the aircraft Try our setting and then Page 29 7 nnt Aircraft Models ASSEMBLY MANUAL Glasair SII Ill feel free to experiment The Glasair is a wonderfully stable and responsive model BENCH PRE FLIGHT O Make sure all clevises have their silicone keeper rings in place and as close to the servo or control arm as possible O Make sure all servos have their output arms held in place by the center screw L Be sure the steering arm has been tightened consider using loctite to secure CO Check that all control surfaces move freely L Check that control surfaces are at the same relative angles i e in line with the flying surface to which they are attached C Check that all control horns are firmly attached L Check that all control surfaces are firmly hinged by tugging on them O Put some fuel in the tank and make sure the plumbing is correct L Check correct operation of control surfaces with your radio that left is left etc Better still have a flying buddy check it TOO CO Go have fun and fly safely Experimental Aircraft Models LLC 1224 Amber Dr Thunder Bay Ontario Canada P7B 6H7 Ph 807 345 4391 Fax 807 683 1216 www RCHomebuilts com Page 30
24. ists adhesive bonding It must be removed from any joint to be glued Failure to remove the covering from glue zones will result in failure of the affected glue joint and likely damage or destroy your model The recommended engines are a 1 08 1 20 two stroke or 1 20 1 40 four stroke Experimental Aircraft Models discourages the use engines larger than this range The Glasair is an aerodynamically clean design that simply does not require larger than the recommended engines Some other notes on engines most of F the engines in the recommended size range weigh roughly the same 28 34 ounces Using a lighter engine will likely require i making up the difference with lead weight Using a larger heavier engine might mean that lead will have to go in the tail For 2 stroke engines the standard muffler will be very difficult or impractical to use because it will project way out of the cowl and might also require modifying the firewall for clearance For this reason 2 strokes should be fitted with a side mount or Pitts Style muffler to keep the installation simple and preserve clean line of the cowl The mufflers on 4 strokes are generally easier to package The Glasair is supplied with an assortment of hardware but a lot of modelers have their own preferences A couple thoughts to keep in mind L Keep close track of all the little screws and hardware sets located within all the large component bags It can be easy to misplace th
25. l of the surface throws at once We recommend the following control surface movement for the initial flights If your transmitter has dual rates use these as a guide L Rudder measured at the top of the Rudder trailing edge each side of center 15mm 22mm s 1 8 O Elevator measured at the trailing edge near the rudder each direction from center 10mm 16mm 3 8 5 8 O Ailerons measured at the wing tip end each side of center 10mm 16mm 3 8 5 8 O Flaps measured at the trailing edge from top of flap to top of wing 7 8 22mm Try using about 7mm 10mm 1 4 to 3 8 for Takeoff and up to full deflection for landing THE FLAPS WILL SLOW THE BIRD DOWN be ready to keep some throttle on FINAL ASSEMBLY 1 WEIGHT AND BALANCE This is probably the most critical assembly step you do Be prepared to add nose weight to the model this would not be unusual as the full scale aircraft is designed to carry over a third of its empty weight forward of the firewall It s a price we pay for being scale We recommend setting the balance of the model at 3 14 aft of the leading edge at the wind root which is approximately the 25 chord line Moving the balance point further forward up to 12 will increase the pitch stability of the model Err in that direction for the first few flights Moving the balance point aft will decrease the pitch stability giving a livelier feel at the risk of be
26. ll in part of the hole to fit the switch r _ w 2s Large hole for combination switch Use for standard switch Note the covering has already been cut as a prelude to sealing the edges middle picture and finally installing the switch Switch Installed O Cut the covering seal the edges T s S _ 7 Before installing the receiver make sure all the servo connections Y harness connections and switch harness plugs are all fully and correctly installed The radio receiver must be wrapped in foam rubber and secured in the fuselage In this case itis lashed to the wing joiner tube sleeve with a couple wrap ties It could have just as easily been secured to the center fuselage bulkhead Radio Receiver Installed O Page 28 a Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 8 Receiver Antenna Routed O Radio Receiver Installed O The radio battery pack must also be isolated in a The receiver antenna can be routed internally through the fuselage and exit out one of the pushrod holes foam rubber wrap and installed securely however we will also take advantage of the weight of that component to help balance the Glasair In this case the battery needed to go between the first and second bulkheads It is offset to Port to counter the weight of the engine cylinder 10 With all the control surfaces now hooked up and with the radio system wired lets check al
27. ly even with the computer the reversing Y is the simplest means to get both servos moving the same direction Plug as both servos into the Reversing Y and make sure the servos are moving the same direction then if needed remove the servo arm from one servo and reinstall it so it matches the position of the other servo You might find this easier to do by temporarily plugging the flap harness into a centering channel like the Aileron Rudder or Elevator channel and then set both servo arms to neutral When you plug the harness back into the flap channel you should see the servos working together throughout the range of flap settings Port Flap Servo LinkageL Starboard Flap Servo LinkageU 11 Before installing the installing the servo covers for the last time give each screw hole a drop of thin CA and when dry drill it again with a 1 5 mm 1 16 drill bit Due to variations in production you may have to elongate some of the holes in the cover to line up with the pre drilled holes in the wing servo bay do this if as necessary and with care so as not to over do it Screw down the servo covers Aileron Servos ga Port Flap Servo O Starboard Flap Servo O Port Aileron Servo O Starboard Aileron O Page 10 JE Aircraft Models ASSEMBLY MANUAL Glasair SII Ill FUSELAGE FRONT END ASSEMBLY Here is another one of those builder selection choices Because the dimensions on the engine mount are
28. mber Dr Thunder Bay Ontario Canada P7B 6H7 www rchomebuilts com win Aircraft Models ASSEMBLY MANUAL Glasair SII Ill About Your Model You have purchased 1 of a limited production run of Glasair SII III RC model Kits in the world You have a very unique model of an Experimental aircraft In the United States Experimental Aircraft are aircraft that are 51 or more built by an individual usually at home and fly under an FAA issued Flight Permit rather than Certification During the past 20 years the most advanced designs in civil aviation aircraft have come from the Homebuilt arena where without the expense of certification and manufacturers liability insurance aircraft of amazing performance and safety could be designed and offered to the public In our mission to support the homebuilder with a scale model of an aircraft project that may have consumed hundreds thousands of hours to complete we have brought together full scale aircraft kit airframe manufacturers with a state of the art world class ARF Almost Ready to Fly model manufacturer Our intent is to provide as scale a model as possible that is as ARF as possible within the confines of limited production run sizes and knowledge that a builder will likely customize to match their own aircraft In that sense this product caters more to the full scale builders and scale modelers than it does out of the box flyers some interesting
29. n Installed amp Retained Starboard Aileron Extension Installed amp Retained All Servos amp Harnesses Checked for OperationU 5 As shipped the servo bays are covered over with Oracover Use a sharp modeling knife to open up these bays then use a trim iron to seal the edges of the Oracover to the servo bays Port Wing Servo Bays OpenedU Starboard Wing Servo Bays OpenedL 6 Next up is to route the servo wiring through the wing and get the servos in position so we can install the control linkages Find the pull through string in aileron servo bay it is wrapped and glued to a balsa stick The other end is tacked inside the access hole in the wing root Remember that the correct servo pair for each wing are the ones that when installed orient the bottoms of the servos toward the wing tip and the pushrod fairings both toward the wing root Securely tape the aileron servo extension plug to Wing Root Tops of servos point this way Page 8 Aircraft Models ASSEMBLY MANUAL Glasair SII Ill the little stick on the string Keep it smooth and torpedo like to make it easier to slip through the wing Pull the lead through until it reaches the flap servo bay Tape the flap servo lead to the aileron lead trying not to make the Torpedo any fatter just longer Continue pulling on the string pushing on the harness and jiggling the wing until the leads com out at the wing root For now it s a good idea to tape the leads to t
30. on Because these will be out of sight inside the wing it is prudent to safety the connections Shown here is a piece of shrink wrap tubing over the connector Page 7 rwan Aircraft Models ASSEMBLY MANUAL Glasair SII Ill joint Another possibility is to use electrical tape We have even seen successful installations that use a loop of dental floss to tie the connection together How ever you do it make sure the connection is retained Now is a good time to double check the operation of the servos and harnesses BEFORE you run the wiring through the wing Use the Y Harness for the aileron servos and the reversing Y Harness for the flap Ln servos So you can confirm the operation of the a complete harness before you install the wiring RECOMMENDED for the aileron servos remove the output arms and displace them by rotating the arms one or two splines FORWARD of the centered position This will provide differential throws ailerons will move UP farther than DOWN and somewhat reduce the need for rudder input when turning amp banking The Reversing Y harness is the simplest means to get both flap servos moving the same direction Plug both flap servos into the Reversing Y then if needed remove the servo arm from one servo and reinstall it so it matches the position of the other servo Port Flap Servo Extension Installed amp Retained O Starboard Flap Servo Extension Installed amp Retained Port Aileron Extensio
31. p and finger tighten the prop nut to hold the backplate snugged against the prop drive washer Double check alignment of the spinner to the cowl it should be Z OK but if it is not you may be able to sand the back of the cowl to make it fit better Page 14 Expe Aircraft Models ASSEMBLY MANUAL Glasair SII Ill With the cowl aligned to the spinner backplate slip some shims scrap balsa or cardboard work great between the cowl and the spinner backplate to hold everything in position Cowl in Position O 13 Use a 1 5 mm 46 bit to drill the 6 cowl mounting blocks for the mounting screws Install the screws as you go to help keep things aligned while the next hole is drilled Remove the cowl and harden each drilled hole with a drop of thin CA Cowl Mounts Drilled amp Hardened O 14 THIS STEP IS FOR 2 STROKE INSTALLATION ONLY Shown below is a 2 stroke installation ona different aircraft the Experimental Aircraft Models RV 7 The size of the model and the engine are somewhat smaller but the installation requirements are the same With a side mounted engine you will want to use a Pitts style muffler with the engine and muffler installed use the paper template method described in steps 2 amp 3 above to locate the exhaust pipes Remove the muffler install the cowl and mark the exhaust tube exit positions This is also a step where the old adage to measure twice before cutting once will come
32. s hole is aligned with the bracket It looks really Pro when the filler is flush with the surface of the cowl and centered in its hole Fuel Filler Hole Cut In Cowl O 4 No matter whether you install a 2 stroke or a 4 stroke engine with a side mounted engine access to the glow plug will be restricted While it is possible to use one of those long stemmed glow lighters to reach through a unsightly hole in the cowl to the glow plug we think a far better solution is a remote igniter located for access 3 Use a drill a Dremel grinder and or various round directly from below In that position it will be out of the line of sight protected and not hard to find by touch After installation cut a clearance notch at the bottom rear edge of the cowl Remote Glow Wiring Installed O 5 Use the paper template method as shown in steps 2 3 to locate any other holes needed Needle valve Remote Glow plug access or other All Cowl Cut Outs Completed O Page 17 Li l Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 6 This step is optional and cosmetic Now all the holes are drilled and dess installed remove everything that is removable and pe PAINT the firewall and front end wood structure after all the Glasair s are all metal and Fiberglass airframes Use fuel proof dope like Sig or Brodak or polyurethane paint in the color of your choice While you are at it spray clear works well to fuel proof some of
33. s to improve accessibility 1 The Glasair has a very large cowl that prevents direct access to the fuel filler so we will install a remote fuel filler Shown here is a Great Planes Easy Fueler Valve similar products also available from other sources shown installed on a plywood mount epoxied to the upper starboard side of the firewall The valve is positioned so that is flush with the surface of the cowl It is shown on the Starboard side but could have just as easily been put on the bottom where it would be out of sight but harder to access or on top of the fuselage With our 3 vent tank the filler valve will be used to fill the tank through the Muffler Pressure line Fuel Filler Valve Installed O 2 After installing use the paper template method to locate a cut out in the cowl side this step is with the cowl removed Cut the appropriate size round hole in a piece of card stock Center that over the filler valve and tape it to the side of the Page 16 rwn Aircraft Models ASSEMBLY MANUAL Glasair SII Ill fuselage Flip the paper template back and side the cowl into position With the cowl aligned with at least 3 cowl screws extend the template over the cowl and mark the position of the clearance hole on the cowl Fuel Filler Position Marked on Cowl O files to carefully cut the hole in the cowl and bring it up to size Go slowly here repositioning the cowl over the mounting bracket to assure that the acces
34. small copper tube ferrules foe ae ae over the cable Next route the cable Use adjustable clevis es through the outermost steering arm _ ee k hole then run the cable back through the ferrule and crimp the tube Repeat for the cable at the other end of the steering arm At the servo end install the adjustable At Steering Arm end slip ferrule over cable clevis half way onto the threaded brass Slip cable through outermost hole of steering arm coupler then install the clevis to the then slip cable back through ferrule and crimp innermost available hole on the servo arm A note on steering use the innermost available servo output a little nosewheel steering goes a LONG way Too much steering motion will make the Glasair hard to control Route both pull cables through the forward fuselage and back to the servo making sure the cable does not foul anything along the way Again slip the ferrule Dam over the cable slip the cable through the brass i coupler an back through the ferrule but DO NOT CRIMP YET Repeat the process for the other cable getting it ready but stopping short of crimping it With the servo centered take you best shot at centering the nose wheel then crimp the ferrules Before you fly take the Glasair out on the driveway or other smooth surface and roll it back an forth with the radio turned on and the rudder servo centered Adjust the cables so that the Glasair rolls straight with the rudder control and trim
35. square it is possible to install the engine either side mounted piston horizontal or inverted and we have customers who have done it either way The installation we will show here is side mounted it hides the engine nicely and will make some of the subsequent assembly choices a little more straight forward Certain details of the engine installation will vary depending on whether you use a 2 stroke or 4 stroke engine We will cover both installations noting any peculiarities encountered 1 First step in the fuselage assembly is to remove the canopy hatch Near the back of the cabin you will find a slightly larger screw than the canopy screws lower on the fuselage than the canopy screws Remove the screws one per side from both sides and lift the back of the hatch rotating the hatch away from the front dowels Put the canopy hatch and the screws aside in a safe place out of the way Canopy hatch removedO Page 11 Expe va Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 2 Using a straight edge check the contouring of the cowl mounting blocks relative to the line of the fuselage In the picture to the right the block has been sanded and tapered to match the fuselage Check correct all six mounting blocks if they need it IF you have to sand the surface then re seal the wood afterwards with a few drops of thin CA Cowl Mounting Blocks x 6 fitted 3 As mentioned in the introductory comments we welcome feedba
36. the stabilizer with the wing and prep the stab for installation Slide the horizontal stabilizer remember which side is the top into the fuselage and install the wing joiner tube Temporarily install the elevators then use some small wood or cardboard scraps as shims to center the elevators to the fuselage Stick a straightpin through the rudder post and into the stab to hold its centered there Next step is to align the stab with the wing tube Measure from the back side of the wing tube to the hinge line of the stab on each side Realign the stab until the measurement is the same on both sides Stabilizer Aligned O Page 20 ae Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 8 Use a felt tip pen to mark the position of the aligned stabilizer with the fuselage The Ultracote covering MUST be removed between these two lines Use the small soldering iron to burn amp seal the covering along the marker lines remove the covering from the center of the stabilizer then wipe off any remnants fo the marker Covering Removed O 9 Install the vertical fin and mark its intersection with the top of the fuselage Again this is where the Ultracote must be removed from the bottom of the fin and the top of the fuselage to assure a great bond Use the small soldering iron to burn amp seat the covering along the marker lines remove the covering from the top center of the fuselage and from the fuselage under the base of the fin
37. the unreachable nooks and crannies of the forward fuselage behind the firewall too Front End Painting Completed FUSELAGE amp TAIL ASSEMBLY A note about rudder and elevator pushrods The hardware shown above is supplied with the kit and is perfectly adequate for controlling your Glasair However as mentioned in the introductory comments if you intend to fly your Glasair at an IMAA event they will insist that you have 3mm or 4 40 sized control hardware If you have one of the early Glasair kits Supplied around January 2007 your kit has also been supplied with pull pull cable for the rudder However this is not really a good fit with the kit because the rudder servo is substantially offset from the centerline Page 18 Aircraft Models ASSEMBLY MANUAL Glasair SII Ill of the fuselage Thus this manual is going to show the construction of pushrods for the elevator and rudder using 4 40 rod ends affixed to s dowel rods 1 We want the linkages to overhang past the dowel by about 150mm 6 We also want the linkages to be anchored in holes at least 30mm to 40mm 1 2 to 1 6 from the end of the dowel rod Thus start by bending all the EEN linkage rods as shown The rudder and one of meg the elevator links should be about 180mm 7 ee Goal zei from the pin to the bend the second elevator N rod should be about 10mm g longer Drill holes in the dowel rods to suit Use Medium CA to a
38. urface 1 Remove the aileron and remove all of the hinge points Mix a small batch of epoxy and using a toothpick drop some epoxy down into each hinge pocket hold the surface with the hole pointing up so the epoxy can flow down into the hole Put a second drop in each pocket if needed One at a time push the hinge points into their pockets if the epoxy purges out of the hole then back out the hinge point wipe the excess epoxy off then reinsert it Inspect each hinge to see that it is square to the surface Then pivot the hinge and check again to see it is square Press the surface up against a straight surface to assure the hinges are all seated at the same depth Port Aileron Hinges Installed Starboard Aileron Hinges Installed O 2 When the epoxy is cured carefully check the movement of each hinge point You may have to carefully pop the movable end of the hinge point loose from any stray epoxy that has gotten into it Go slowly until each of the hinges moves freely Your servos and your battery pack will thank you Port AileronO Starboard AileronU Page 6 Expe Aircraft Models ASSEMBLY MANUAL Glasair SII Ill 3 Next step is to install the aileron to the wing The hinge points do not bottom out on the wing side so it is important that the hinge pocket be wetted out nicely Install the hinge points onto the wing side set the hinge gap to no more than 1 mm 32 A good way to do this is by using a

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