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U.S. Aircore Trainer 40 User Manual

U.S. Aircore Trainer 40
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U.S. Aircore Trainer 40 Specifications

General IconGeneral
BrandU.S. Aircore
ModelTrainer 40
CategoryToy
LanguageEnglish

Summary

Introduction and Warnings

Warning!

Critical safety notice about the R/C kit and model, emphasizing responsibility for safe use.

Introduction

Welcome and overview of the U.S. Aircore Trainer 40's features and benefits.

Assembly Essentials

Precautions

Critical build and safety guidelines for assembling the model correctly.

Required Items

List of materials and components needed for assembly.

Required Tools

List of tools necessary for building the aircraft.

Engine Selection

Section One: Sub-Assemblies and Practice

Step 1: Read Instructions

Familiarize with manual, charge radio system, and understand techniques.

Step 2: Remove Parts

Unpack and identify all components by comparing them against the parts list.

Step 4: Prepare Aircore Parts

Prepare parts for bending by breaking in scores, potentially using heat.

Step 5: Assemble Power Cartridge

Begin assembly of the power unit by gluing plywood halves and doublers.

Power Cartridge, Spar, and Fuel Tank Assembly

Step 5: Assemble Power Cartridge (continued)

Complete power cartridge assembly, including nose gear block.

Step 8: Build Wing Spar

Construct the wing's main spar by gluing spars to dihedral braces.

Step 9: Assemble Fuel Tank

Construct the fuel tank assembly using plastic tube and rubber stopper.

Section Two: Building the Wing

Step 9: Assemble Fuel Tank (continued)

Finish fuel tank construction by connecting tubing and stopper.

Step 10: Working with Contact Cement

Guidance on using contact cement for AirCore material assembly.

Step 1: Construct Ailerons

Build the ailerons by preparing hinge strips and attaching them to wing bottoms.

Wing Construction: Ailerons and Spars

Step 1: Construct Ailerons (continued)

Attach ailerons to wing trailing edges, ensuring proper hinge alignment.

Step 2: Exercise Wing Leading Edge

Prepare the leading edge for folding by exercising score lines.

Step 3: Mark and Install Spar Alignment Strips

Mark spar locations using pin-holes and place alignment strips.

Wing Spar and Rib Assembly

Step 3: Mark and Install Spar Alignment Strips (continued)

Secure spar alignment strips to create the spar slot.

Step 4: Construct and Install Wing Center Ribs

Assemble wing center ribs and install them onto the wing bottoms.

Step 5: Install Leading Edge Strips and Gussets

Add leading edge strips and gussets to the wing structure.

Completing the Wing Structure

Step 5: Install Leading Edge Strips and Gussets (continued)

Finalize leading edge components, ensuring proper fit and glue.

Step 6: Install Wing Spar

Secure the main wing spar in place using contact cement.

Step 5: Trial Fold the Wing

Test wing fold alignment to ensure all parts fit correctly before gluing.

Step 7: Fold Wing Tips

Shape and glue wing tips, then trim excess material for a clean finish.

Step 8: Check and Fix Wing Warp

Correct wing warpage by checking alignment and applying corrections.

Wing Final Assembly

Step 8: Check and Fix Wing Warp (continued)

Warp correction methods using delaminating and reglueing.

Step 9: Install Aileron Torque Rods

Fit and connect aileron control rods, ensuring proper orientation.

Step 10: Install Center Wing Wrap

Apply wing wrap material to the center section of the wing.

Wing Wrap and Servo Installation

Step 10: Install Center Wing Wrap (continued)

Secure the wing wrap, ensuring a tight and neat fit.

Step 11: Install Aileron Servo

Mount the aileron servo by cutting a hole and securing it with a servo block.

Section Three: Building the Fuselage

Step 1: Install Fuselage Doublers

Add internal fuselage supports by gluing doublers to the inside.

Step 2: Install Rail Doublers

Attach rail support pieces to the fuselage for structural integrity.

Fuselage Structure Assembly

Step 2: Install Rail Doublers (continued)

Secure rail doublers to the fuselage, ensuring proper alignment.

Step 3: Install Side Boards and Nose Reinforcement

Add fuselage structural components like side boards and nose reinforcement.

Step 4: Install Fuselage Bulkheads

Fit internal bulkheads into the fuselage structure for support.

Step 5: Install Nose Reinforcement

Add front fuselage reinforcement for added strength.

Fuselage Base and Saddle Construction

Step 5: Install Nose Reinforcement (continued)

Finalize nose reinforcement by gluing it securely in place.

Step 6: Install Floor Board

Add the fuselage floor by placing and gluing the board into notches.

Step 7: Fold Fuselage Bottom

Shape the fuselage base by folding and trial fitting the bottom sections.

Wing Saddle and Tail Surface Preparation

Step 7: Fold Fuselage Bottom (continued)

Complete fuselage base assembly by gluing the front and middle flaps.

Step 8: Install Wing Saddle Doublers

Add wing support doublers to the fuselage sides for a stable mount.

Step 9: Install Wing Saddle Bulkheads

Fit wing saddle bulkheads into the fuselage for proper wing alignment.

Fuselage Details and Window Installation

Step 9: Install Wing Saddle Bulkheads (continued)

Secure wing saddle bulkheads, ensuring correct alignment with the wing saddle.

Step 10: Install 6-mil Wing Saddle Doublers

Add more wing saddle supports by installing the 6-mil doublers.

Step 11: Install Windows

Fit fuselage windows, including windshields and side windows.

Tail Surface Preparation and Landing Gear

Step 11: Install Windows (continued)

Glue fuselage windows securely in place.

Step 12: Install Wing Hold Down Dowels

Add dowels for wing attachment to the fuselage.

Step 13: Build Stabilizer and Elevators

Prepare tail surfaces by slitting flutes for hinges on stabilizers and elevators.

Elevator Controls and Fin/Rudder Preparation

Step 13: Build Stabilizer and Elevators (continued)

Assemble tail surfaces by installing dowels and joining stabilizer halves.

Step 14: Install Elevator Joiner Wire and Control Horn

Connect elevator controls by installing joiner wire and control horn.

Tail Surface Controls and Landing Gear Assembly

Step 14: Install Elevator Joiner Wire and Control Horn (continued)

Mount the elevator control horn securely to the elevator surface.

Step 15: Install Elevator Control Horn

Finalize elevator control mounting by attaching the control horn.

Step 16: Prepare Fin and Rudder

Prepare tail fins and rudder by slitting hinge flutes and installing dowels.

Tail Wheel and Final Tail Assembly

Step 16: Prepare Fin and Rudder (continued)

Install rudder controls and connect the rudder to the servo.

Step 17: Install Tail Wheel

Add the tail wheel assembly by creating and installing the tail gear wire.

Tail Wheel and Tail Section Finishing

Step 17: Install Tail Wheel (continued)

Complete tail wheel installation by bending wire and securing the bracket.

Step 18: Attach Stabilizer and Fin

Mount tail surfaces by attaching the stabilizer and fin to the fuselage.

Step 19: Finish Tail Section

Apply tail trim strips to the leading edges of the stabilizer and fin.

Step 20: Assemble Main Landing Gear

Build the main landing gear by slitting struts and assembling the components.

Landing Gear and Engine Installation

Step 20: Assemble Main Landing Gear (continued)

Finalize main landing gear by gluing struts and installing wheels.

Step 1: Install Engine on Power Cartridge

Mount the engine onto the power cartridge, ensuring proper fit.

Engine and Servo Installation

Step 1: Install Engine on Power Cartridge (continued)

Attach fuel lines to the engine and carburetor.

Step 2: Install Servos

Prepare servos by installing grommets and mounting them to the power cartridge.

Servo and Fuel Tank Installation

Step 2: Install Servos (continued)

Mount the remaining servos to the power cartridge.

Step 3: Install Fuel Tank

Place the fuel tank into the power cartridge.

Receiver, Battery, and Servo Connections

Step 3: Install Fuel Tank (continued)

Secure the fuel tank in the power cartridge and attach fuel tubing.

Step 4: Install Receiver and Battery

Mount electronics by installing hook and loop material and securing receiver and battery.

Step 5: Hook Up Servos

Connect servos to the receiver, using extension wires and bundling them.

Radio Switch and Servo Setup

Step 5: Hook Up Servos (continued)

Bundle servo wires neatly for proper installation.

Step 6: Install Radio On/Off Switch

Mount the power switch on the fuselage or power cartridge.

Step 7: Set Up Servos

Perform initial servo calibration by centering controls and setting arm positions.

Throttle Linkage and Nose Gear Installation

Step 7: Set Up Servos (continued)

Finalize servo adjustments by checking arm positions.

Step 8: Install Throttle Linkage

Connect the throttle control linkage, including clevis and Z-bend.

Step 9: Install Nose Gear

Fit the nose gear assembly through the fuselage block and attach steering.

Nose Gear and Main Landing Gear Mounting

Step 9: Install Nose Gear (continued)

Finalize nose gear installation and connect steering linkage to rudder servo.

Step 10: Mount Main Landing Gear

Attach the main landing gear to the fuselage using rubber bands or bolts.

Landing Gear Adjustment and Power Cartridge Installation

Step 10: Mount Main Landing Gear (continued)

Adjust landing gear wheel collars for proper plane leveling.

Step 11: Install Power Cartridge

Insert the power cartridge into the fuselage, trimming as necessary.

Power Cartridge Securing and Propeller Installation

Step 11: Install Power Cartridge (continued)

Secure the power cartridge with screws, ensuring clearance for components.

Step 12: Install Prop and Spinner

Mount the propeller and spinner onto the engine.

Propeller Balance and Model Balancing

Step 12: Install Prop and Spinner (continued)

Ensure the propeller nut is tightened securely.

Step 13: Balance Model with Power Cartridge

Achieve proper balance by adjusting the power cartridge position.

Control Linkage and Radio Checks

Step 13: Balance Model with Power Cartridge (continued)

Adjust balance as needed, then remove the wing.

Step 14: Attach Pushrod Clevis

Connect control pushrods by attaching clevises to horns.

Radio System Check and Antenna Installation

Step 14: Attach Pushrod Clevis (continued)

Finalize pushrod connections, ensuring secure clevis attachment.

Step 15: Check Your Radio

Verify control surface function and directionality.

Radio System Calibration and Antenna Mounting

Step 15: Check Your Radio (continued)

Test all control surface movements and throws for proper operation.

Step 16: Install Antenna

Mount the antenna wire through the fuselage and connect it to the tail.

Section Five: Precautions & Safety Guidelines

Storage and Transportation

Proper care for the model during storage and transportation to prevent damage.

Avoid High Temperatures

Prevent heat damage to the model by avoiding storage in hot vehicles.

Repair Tips and Learning to Fly

Repair Tips

Methods for fixing damage to AirCore material and internal components.

How to Learn to Fly

Guidance for new pilots on finding instruction and resources.

Preflight Checks and Safety

Charge Batteries

Battery charging procedures for transmitter and receiver.

Balance Propeller

Essential propeller balancing to prevent vibration and damage.

Find Safe Flying Site

Selecting a suitable flying location and joining local clubs.

Ground Check Model

Inspecting the assembled model for correct radio and engine installation.

Radio Range and Engine Safety

Range Check Radio

Test radio control range with the engine running.

Engine Safety Precautions

Critical safety measures for operating the model's engine.

Flying Operations

Taxiing

Ground handling and steering practice.

Takeoff

Procedure for launching the aircraft smoothly.

Flight Maneuvers and Landing

Flight Maneuvers

Basic flight techniques and control coordination.

Landing Procedure

Safely bringing the aircraft down for a smooth touchdown.

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