1/12 cap 232 - micron radio control : micron radio control · thank you, for purchasing this...

CAP 232 1:12 Scale micro

V2.0

© StevensAero.Com 1/23/2006 Span 24.2” / Length 22.2” / Area 105 Sq.” / Weight 6-7oz

© StevensAero.Com 1/23/2006

REQUIRED TO COMPLETE KIT Kit Contents:

Computer Drawn Plan Sheet Illustrated Instruction Manual (6) Laser Cut Balsa Parts Sheets (See Parts Inventory Sheet) 1 - Clear Canopy 1 - Cowl Assembly 2 - 3/16” Square x 18” Balsa Sticks 2 - 3/16” Square x 12” Balsa Sticks Hardware Bag • • • • • • • • • • •

1 - 1/32” Laser Cut Plywood Parts Sheet 2 - 1/8” x 3” hardwood wing dowel. 1 - 1/8” x 2” hardwood wing dowel. 1 - ¼” x 3” LPS Motor Mount. 1 - #16 Rubber Bands (10). 2 - 0.070” x 3” Carbon Landing Gear. 2 - 1/32” x 12” Music Wire. 1 - 3” Length Heat Shrink Tubing. 1 - 1/16” x 4” aluminum tube. 1 - 12” Length of pull/pull guide tubing. 2 - 1”x3/4” CA Hinges

Suggested Finishing Items:

Dubro DUB100MW 1” Mini lite wheels (2). Dubro Micro Pull/Pull Assembly DUB846. 1 Roll Solar Film So-Lite or Nelson Lite Film.

Suggested Radio Gear:

3 - GWS Pico BB Servos / 4.9g Cirrus/E-Hobby (can be made to fit) 1 - Sub-micro Receiver 8g or less (Dual Conversion Recommended) 1 - GWS 2-5 Amp Micro ESC 1 - GWS LPS-RLC-C 4.8v (6.0:1) 1 - GWS LPS motor Heat Sink 1 - GWS 7x6 Slow-Fly Prop 7 - 8 Cell 370 MAH NIMH Battery (Good) – 2S1P 7.4v Kokam 340mah Lipoly (Best)

Things you may need:

Thin CA (super glue) Five Minute Epoxy Plastic Model Cement Wax Paper or Plastic Wrap Razor Blade(s) Fine Grit Sand Paper Flat Rat Tail File or Emery Board Clear Tape Balsa Wood Filler Sewing Thread

© StevensAero.Com Page 4 1/23/2006

GENERAL ASSEMBLY INSTRUCTIONS: Thank you, for purchasing this Stevens AeroModel 1:12 Scale Cap 232 (MICRO). …Unlike anything you have ever built. This outstanding kit has raised the bar for laser cut precision in the modeling world and features: Precision all laser cut and completely interlocking components that self-align for a quick and accurate assembly. Revolutionary interlocking Warren Truss fuselage and tail feathers for a light, rigid, and warp resistant assembly. Computer drawn plans and step by step illustrated instruction manual. Please keep in mind that while small and cute like a “park flyer” this is a sport plane and behaves as such. Therefore we recommend this kit to the advanced sport pilot. The tiny airframe, wheels, and building materials exclude this model from flying from anything but and improved surface (read: sealed asphalt, concrete, etc..). A good rule of thumb –if you cannot readily taxi and take off from the surface – do not attempt to land there! We hope you enjoy this model as much as we have. Sincerely, Bill Stevens [email protected] Stevens AeroModel “Built to Fly” 4550 Beaumont Rd. Colorado Springs, CO 80916 General Assembly Tips

READ THE INSTRUCTIONS and the plan sheet prior to starting any work! Tape plans to work table. Cover with wax paper or plastic wrap. Join all joints with Thin CA unless otherwise specified. DO NOT REMOVE THE PARTS FROM THE BALSA SHEETS UNTIL REQUIRED! DO NOT FORCE THE FIT – when in doubt double check your parts and remove material

should not be required. If you feel that you have a poor connection check first to see that the part is not upside down. Next, referenced each piece against the plan sheet.

This is very important so I’ll say it again – Prior to gluing, test fit and match parts over the plan sheet to ensure you have the correct pieces and orientation.

Making solid glue joints: Hold parts together on top of plan sheet using moderate pressure to fit parts - wick thin CA into joint. (There is no need to pin parts to work table as all pieces interlock and self - jig.)

Tail Feathers

Build the Rudder, Vertical Stabilizer, Elevator, and Horizontal Stabilizer. Parts are grouped according to tail section component on the 3/32” balsa sheet. Work with each component separately. Assemble over plan sheet, removing only those parts necessary to complete each individual component. Though the parts fall together and self jig, pay particular attention to making solid glue joints. (note: at the time of printing your plan sheet may reflect the old-style tail feathers use the included update sheet to replace the parts overlay for the tail feathers as illustrated on the plan sheet)

F

Elevator

Horizontal Stab.

D

A

D

A

E E

B B

C

F

C

F F

CC

EE

BB

D D

Vertical Stab.

FF

I

I

E

E

G

G

H

H

Elevator Joining Tube. Locate the provided 1/16” aluminum tube - rough the surface with fine grit sand paper to remove dirt, oil, and debris, from the tube. Bond elevator halves over plan sheet using thin CA tack the joining tube to each elevator halve and allow to dry. Once dry use a small amount of 5-minute epoxy to create a fillet between the wood and the metal tube.

Sand all surfaces with fine grit sandpaper and bevel / taper hinged surfaces in preparation for your preferred hinging method.

Fuselage Fuselage components are exceptionally brittle until the entire assembly is complete. Handle parts accordingly and do not force the fit!

Join over plan sheet F16A and F16B to produce 2 F16 fuselage side sheets.


Assemble formers F4, F5, and F6. Join over plan sheet F4A, F4B, F4C, F4D, F5A, F5B, F5C, F5D, F6A, F6B, F6C.

Assemble fuselage sides over plan sheet. Parts are grouped on the 3/32” balsa sheet. Make 2 sides.

Locate Firewall parts F1 and F2 – if using the recommended LPS drive insert the 10mm balsa square with the ¼” hole into both F1 and F2 (Hole should be positioned such that it is at the lower part of the square when joined to F1/F2. Join fuselage sides to F1, F2 and F1A. Test fit parts before gluing.

F1 F2

F1A

LPS Adapter x2


Install F3A, F3B and servo rails SR1-SR2. Site fuselage construction over plan sheet top

view to ensure straight and true assembly. Join each of these to the fuselage sides in their respective positions. Note the servo rails are composed of a top piece SR1 and bottom 3/32” doublers SR2.

Glue F14 3/32” stringers to top of F1, F2, and F3A.

Pinch fuselage sides together at tail position, using a flat rat tail file or emery board bevel the notches and alignment tabs in the fuselage to better accommodate formers F4, F5, and F6.


Test fit former F4 and F15 to fuselage. Align over top view on plan sheet and secure with

thin CA. Hint: Sand a slight bevel on sides of former F4 to aid fit. Again, do not force fit!

Proceed to install former F5 and F6 inserting F13 stringer along the bottom of the formers to jig the assembly. Initially test fit F5 and F6 then glue F5 and F6 to fuselage sides - then glue (if the fit is too snug bevel the notches with a rat-tail file or emery board). Only glue F13 where it makes contact with F4, F5, and F6 – Do not glue F13 to fuselage sides at this time!

Test fit former F7. Capture aft section of F13 between fuselage sides, do not glue at this time.


Place some sort of weight over servo rails. Using a builders square hold tail section 90

degrees to building table and glue F7 and F13

Add tail gear block F11 to aft section of F13 inside fuselage.

Laminate F10 in position over aft section of fuselage. Important - Key F10 to top of F7.


Laminate F9 to F10, key to F7. DO NOT align with holes provided in F10 but key to F7.

Test fit F12 to F8. Lay F8 on building table, press F12 into F8 and glue.

Test F12/F8 assembly to formers F4, F5, and F6 (do not glue until specified). Align outer edge of F8 with outer edge of F9 and tack glue just the aft end of both parts.

Test fit horizontal stabilizer in the slot created between F10 and F8. Snug F6 against F12/F8 assembly – remove horizontal stab and glue. Finish gluing parts F8 and F9

Glue F12/F8 assembly to F4 and F5.


Laminate finishing blocks to top of F8.

Sheet fuselage sides with F16.

Sheet fuselage top/front with F17. Test fit – then secure one end with thin CA. Next, gradually tack down the sheets to the formers with thick CA.


Key F3C to fuselage and glue to F4.

Prior to sheeting turtle deck, route included elevator and rudder pull / pull guide tubing. Run a short length of tube for the elevator (it doesn’t matter what side you run it out of) flush with F3C and secure through hole in one side of F5 (leave about 1/8” beyond F5) where your elevator pull / pull cable will exit through turtle deck. The remainder of the pull/pull tube should be installed flush with F3C and extend through the elongated slot in F13 approximately 3/8” below fuselage. Secure Pull/Pull tubing with a small dab of thin CA then create fillets of 5-Minute epoxy at each plastic to balsa joint.


Sheet the Turtle Deck with F18 (It helps to pre-sand the turtle deck slightly) Try to sheet

the turtle deck dry – as a last resort use rubbing alcohol to soften wood and facilitate bending around the radius of the turtle deck. Test fit – then secure one end with thin CA. Next, gradually tack down the sheets to the formers with thick CA. Glue to formers F6, F5, and F4. Glue to F3C. Finally, trim and sand leading edge of turtle deck sheeting flush with F3C.

Carve and sand aft section of turtle deck round.

Battery Tray: Install the battery tray (located on the 1/16” balsa sheet and designated as “Battery Tray”) inside the fuselage spanning formers F2, F3a, running span-wise along the stringers F14.

BATTERY TRAY


Verify length and sand the ¼” motor mount dowel to achieve a snug fit with the

appropriate cut outs in fuselage formers F1 / F2. Prior to installing in fuselage - the dowel must be turned down to fit the LPS drive – to do this chuck the dowel into a power drill and sand off material reducing the diameter of the dowel to fit snug with the LPS drive. You only need to reduce 1” of the dowels diameter and must leave the remainder of the dowel ¼” in diameter to properly fit within the firewall mounts F1 and F2. Be certain to test fit the motor mount stick to the LPS Gearbox –install motor mount through formers (don’t force the fit) and secure with thin CA. Support the backside of the motor mount stick when sliding the IPS gearbox on or off the mount! The fuselage firewall will also accommodate the following drive systems – Astro 010 Direct Drive / GWS IPS Motor – Gearbox / GWS EPS Motor – Gearbox. We have found the 4.8v LPS Drive / Direct Drive Astro 010 to net the best performance and highly recommend the 4.8v LPS Drive as the all around best fit for this airframe.

F1 F2

LPS Adapter: Support added for LPS drives via LPS adapter plug. To fit LPS drives simply sand down one side of a length of 1

4" dowl to fit the drive gearbox and insert un-sanded 1

4" dowel through firewall using LPS adapter.

Support added for direct drive AstroFlight 010 motors.

Allows the use of two 1/8" dowels (not supplied with the kit) to mount a direct drive Astro 010 BL motor.

Insert two 18" dowels of

the appropriate length (use rolled plan sheet) through firewall and strap Astro 010 to dowels.


Wing Assemble wing upside down - all rib pieces have built in jig and allow for a straight and true wing final assembly when built in this fashion. Do not break jig off of rib pieces until you have completed wing assembly.


Join S1 to S2 to create main spar.

Key R1, R2, R3, R4, R5 and R6 onto main spar. Align over plan sheet upside down and glue.

Build up landing gear block as shown on plan sheet. Laminate LG3A and LG3B to LG1 – Finish the assembly by laminating the LG2 over LG3A and LG3B opposite LG1.

Test fit and assemble LG4, LG5, and LG6 to landing gear block. PAY ATTENTION to

the location of the landing gear slots – the landing gear slots narrow at the top and are spread apart the furthest at the bottom. Once satisfied with assembly align over plans and secure with thin CA.

LG4

LG4LG5

LG6

LG5

LG6

LG5

LG6

Align landing gear block between ribs R1 and wing spar – Snug the parts into position and glue.

Double Wing Spar with S3 opposite landing gear block.


Fit parts W1, W2, and W3 to wing aligning ribs over plan sheet but do not glue at this time. W2 sets the spacing between ribs R1 and R2. W3 sets the trailing edge spacing of the remaining ribs.

Once satisfied with the fit make sure the wing is resting upside down on table and all rib jigs are flat with table surface. Glue W1, W2, and W3 to wing assembly. Sand W1 flush with inside surface of R1 and outside surface of R2.

Locate the 18” long 3/16” stringer. Lay side by side on table overlapping ends by 1” – using a straight edge razor blade cut a angle across the overlapping ends. Join stringers along this angle with thin CA to create 3/16” leading edge.


Center the leading edge with the wing assembly and glue into position – first across the landing gear block and R1 – Move on to the remainder of the ribs being mindful of aligning the wing and ribs to the plan sheet. (Hint: Using a straight edge razor cut from the back side of the leading edge ½ way through leading edge - where indicated in photo – this will help the leading edge conform to the wing without ranking the ribs.)

Remove the 1/16” x 3/32” turbulators from the 1/6” parts sheet – Install turbulators to wing using groves provided in ribs.

Laminate the W7 pieces together in pairs of two to create the aileron servo block.

Sand to fit and slide into provided holes on ribs R1 – Remember your orientation! – do not glue servo block in upside down.

With wing upside down on flat surface, slide W4 into position to create trailing edge of wing - double bottom of W4 with W5 (1/32” ply on underside of wing trailing edge).

W5

W4

W5

Locate the torque rod holes in R1 and R2 - harden the wood around the holes using thin CA. Run a small length of 1/32” music wire through each hole to verify that the torque rods, once installed, will move freely. If using the Dubro Micro Aileron System now is the time to install the torque tube sleeves by enlarging the holes to fit the poly tubing.


Build ailerons using parts A1 and A2 reference plan sheet for positioning– make a right

and left aileron. Friction fit all parts together, prior to committing with glue, making a right and left side over the plan sheet then add the 3/16” aileron leading edge which creates your hinge line – go slowly and makes sure not to twist or warp the aileron.

A1

A1

A1

A1

A1

A1 A1

A1 A1

A1

A2

A2

The inside rib bay of the ailerons will form the torque rod block and requires laminating part A4 – to the innermost A1 aileron rib then laminating A3 to A4 creating the inside edge of the aileron. Remember create a right and left side. Nest a 3/8” length of poly tubing within the gap created by A4/A3 – this tube allows for solid control of the aileron and minimizes binding – do not leave this tube out! See detail below to get a better idea of how the aileron torque rod assembly functions.

A4

A3

W1

A1

A3A4

W2

W7

W7

W4

Heat Shrink Tube

W5 Doubles W4 Underside of Wing

Note: Nest a 38" length of 1/32" ID tubing inside pocket created by the lamination of parts A1, A3, and A4. This will act as a bearing for the torque rod and prevent binding.


LE1 keys to the gear block parts LG5 and LE2 is laminated to LE1. LE1 and LE2 have two 1/8” holes bored through them to receive two 3/8” lengths of 1/8” OD dowel which act as wing center locating pins (these are non structural and not designed to handle in-flight loads without the use of rubber bands to mount the wing). Follow the updated diagram below for positioning information for LE1 and LE2. Install each 3/8” length of 1/8” dowel after you have covered the wing. Test fit to F2 then harden the receiving holes in F2 with thin CA. Parts LE1 and LE2 are located on the 1/8” balsa parts sheet.

R1

LE1

LE2

LE1LE2

LG5 LG5 LG5

Wing center locating dowels.Cut a 3/8" length of 1/8" OD Dowel and insert into wing leading edge after covering.


Landing Gear The carbon landing gear supplied with this kit offers great strength and keeps the weight to a minimum. However, sharp/abrupt impacts with the ground may cause the gear to snap exploiting a weak spot in the carbon rod (a nick or razor cut will create a weak spot). If you are not concerned about counting every gram (or plan on exceeding the maximum recommended AUW of 8 oz) you may wish to substitute a more durable but heavier 1/16” music wire gear in place of the carbon composite.

Cut or Verify that 0.070” carbon rod is cut to appropriate size. Sand at least 1” along ends of carbon rod with fine grit sand paper to facilitate bonding when glued.

Bend 1/32” music wire as outlined on plan sheet sand bond area of music wire with fine grit paper and lash to carbon rod with thread. Soak threads with CA glue.

Laminate balsa to create a right and left wheel pant – refer to plan sheet. Sand to desired shape. Note the groove in the outside of the wheel pant to capture the axle. Laminate parts in the following sequence WP1 – WP2 WP3 – WP3 – WP3 – WP4. Reverse sequence to create opposite wheel pant.

Slide wheel pant partially onto music wire axle – Slide 1” Dubro Mini-Lite wheel onto axle – continue to slide wheel pant onto axle. Nest the axle in the side groove of the wheel pant and secure with a thin bead of epoxy. Place a dab of epoxy on the outer most portion of the axle where it comes in contact with the wheel pant.

Slide completed landing gear into landing gear block in wing check the fit and alignment – remove then re install with a smear of 5-min. epoxy – do not use CA as it will make the gear brittle.

Using plan sheet as a reference, bend a length of 1/32” music wire as indicated to create a tail skid – install optional tail gear block and wheel if so desired.

Canopy/Cowl

Trim canopy to fit – a scribe line on the molded part is provided to assist with this task. The cowl assembles in two pieces one nesting inside the other along a grove in the

molded parts. Carefully trim each part and test assemble cowl to fuselage. When satisfied with fit, bond parts with liquid model cement fill seam and paint to match color scheme of model. Cut out vent holes in cowl to provide cool air to motor. IMPORTANT! Only use liquid model cement on cowl CA will cause the plastic to become brittle. Additionally, when painting the cowl start with a light mist of primer – then build up your paint in light coats allowing each layer to dry completely before applying the second coat. APPLYING PAINT TO THICK WILL MELT AND DEFORM THE STYRENE – we recommend Testors® brand model paint.



Final Assembly

Cover and trim the entire model with Nelson Lite-Film or Solar Film So-Lite. Caution heavier covering materials will crush the structure.

Cut provided CA hinge material into small strips (as illustrated on plan sheet). Determine hinge points for control surfaces (use the plan sheet as a guide) then pre-slot

elevator, rudder, and wing assemblies at hinge points to accept CA hinges. Sand ends of wing dowel smooth then insert wing retaining dowel rods into holes

provided in fuselage – secure dowels with thin CA. First, Slide elevator into fuselage. Then, insert the horizontal stabilizer. Hinge elevator to horizontal stabilizer - secure hinges with thin CA. Center the stabilizer assembly and align square to wing tips. Secure with thin CA. Insert 1/32” ply control horn into horizontal stabilizer on the same side that your pull /

pull guide tube exits the turtle deck – secure with thin CA. The vertical stabilizer keys into the aft section of the turtle deck and the groove in the aft

end of the fuselage. Carefully work the vertical stabilizer into place and secure with thin CA.

Fit CA hinges to rudder and vertical stabilizer – secure with thin CA. Insert 1/32” ply control horn into ruder and secure with thin CA.

Using plan sheet as a guide – make up two aileron torque rods and two aileron push rods. Slide torque rods through holes in R1/R2.

Test fit CA hinges to ailerons and wing – Fit torque rods to ailerons. Secure hinges and torque rods to aileron with thin CA.

Install tail skid assembly by drilling a small hole in the aft end of the fuselage (reference plan sheet) – secure skid with thin CA.

Install main gear – sand 1/16” carbon rod and feed into landing gear block – secure with a small amount of Thin CA.

Fit / mount cowl and canopy to fuselage secure with clear tape. (Remember you may need to allow for access to the canopy area for servo adjustment).

Radio Gear

Install (2) sub micro servos for your elevator and rudder control and (1) sub micro servo for your aileron.

As illustrated on plan sheet, center ailerons and bend torque rods perpendicular to wing. Connect aileron push rods to torque rods using the provided heat shrink tubing to create a flexible joint – shrink tubing and secure ends of tube with thin CA.

Set up pull / pull linkage according to the guide included with the required Dubro DUB846 Hardware. Secure pull / pull crimps with thin CA in addition to crimping!

Mount battery with Velcro to top of wing forward of main spar. Mount receiver with Velcro to underside of turtle deck.

First Flight

For your initial flight balance aircraft 1/8” forward of the main spar. Once you are comfortable with the flight envelope of this model you may slowly move the CG back to achieve more advanced maneuvers. Adjust position of receiver and battery until the proper the CG is attained.

Sight along wings and tail surfaced and remove warps if found. Set aileron throw to 1/8” in either direction. Set rudder throw to 3/4". Set Elevator throw to 1/4” up and down. Choose a calm day for your trim flight! Slowly advance throttle – within a few feet you will be airborne. The cap slows down nicely for landings; however, make your first landings power-on until

you are familiar with the aircraft’s stall. Remember you must fly from a smooth improved surface – Tiny 1” wheels and wheel

pants do not facilitate landing in grass or scrub. Getting Support

Updates to this manual along with FAQ’s and flight tips are continually updated on our web-site at www.stevensaero.com.

For prompt answers to your inquiry we recommend contacting Stevens Aeromodel via e-mail. Comments and support questions will be handled in the order received. The e-mail address for technical support or missing kit items is [email protected].

If you are new to electric r/c we highly recommend a visit to www.ezonemag.com the online forum devoted to electric r/c enthusiasts.

Thank You, Stevens AeroModel wws.stevensaero.com 4550 Beaumont Rd. Colorado Springs, CO 80916


http://www.stevensaero.com/

mailto:[email protected]

1/12 cap 232 - micron radio control : micron radio control · thank you, for purchasing this...

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