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T 5 Minute Epoxy
T # 1 Phillips Head Screwdriver
T Needle Nose Pliers
T Modeling Knife
T Straight Edge Ruler
T (2) 4-1/2" (114mm) Threaded Wires with 90º Bends
T (1) Plywood Servo Tray
T (2) Nylon Adjustable Control Horns
T (2) Nylon Clevises
T (2) Nylon Snap-Keepers
T Masking Tape
T Paper Towels
T Rubbing Alcohol
T Epoxy Mixing Sticks
T Epoxy Mixing Cups
AILERON CONTROL SYSTEM INSTALLATION
YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT:
YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES:
STEP 1: INSTALLING THE AILERON SERVO
T Cut a shallow notch on the inside of one end of the servo tray large enough
for the aileron servo lead to pass through next to the servo.
T Carefully cut a notch in the back of the servo mounting opening in the wing
large enough so that when your servo is installed the servo lead won't be
pinched or otherwise damaged.
IMPORTANT Before gluing the aileron servo tray into place in the next procedure, remember to cut away the covering material
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T Glue the servo tray onto the wing, making sure that the servo tray is centred
over the mounting hole in the wing.
IMPORTANT When gluing the servo tray in place, use a generous bead of
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by the wing's dihedral angle.
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bottom of the servo.
T Install the aileron servo into the servo tray, making sure to drill 1/16" (1.6mm)
diameter pilot holes for the mounting screws.
IMPORTANT Note the orientation of the servo. When installed, the servo
output shaft should be toward the trailing edge of the wing.
Cut
T Slide one hinge into each of the four hinge slots in the aileron, making sure
that you push each hinge in up to the T-Pins.
IMPORTANT Don't glue the hinges into the aileron yet.
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hinge slots in the trailing edge of the matching half of the wing, making sure
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IMPORTANT You may need to cut the slot in the aileron for the torque rod
wire deeper, so that the aileron can be pushed forward enough to ensure
a tight hinge gap.
T Cut out a 1-3/4" (44mm) square piece of wax paper and slide the wax paper
between the torque rod wire and the trailing edge of the wing.
The wax paper will prevent epoxy from gluing the torque rod wire to the
trailing edge of the wing.
T Lightly sand the end of the torque rod wire to roughen the gluing surface.
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T Mix a small quantity of 5 minute epoxy and apply a thin layer to the end of
the torque rod wire and into the predrilled hole and the precut slot in the leading
edge of the aileron.
T Remove the T-Pins and push the aileron up against the trailing edge. There
should be no more than a 1/32" (1mm) wide hinge gap.
T While holding the aileron tight against the trailing edge, pivot the aileron
down 45º and apply 5-6 drops of thin C/A to the exposed area of each hinge,
then turn the wing over and repeat for the other side of the hinges.
T Allow the C/A and epoxy to dry for about 15 minutes, then pivot the aileron up and down several times to free up the hinges.
IMPORTANT Check the integrity of the hinges after the C/A fully cures by gently pulling on the aileron. If one or more hinges
feels loose, apply more C/A to the hinge(s) and allow it to completely cure. The last thing you want is for a hinge to come loose
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T Repeat the previous procedures to hinge the aileron to the other half of the wing.
T Push the aileron and hinges into the corresponding four hinge slots in the trailing edge of the wing.
IMPORTANT Roughening the metal will allow the epoxy to stick better to it. Do not omit this procedure.
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