Engine: .46−.55 cu in (7– 9 cc) 2-stroke

or .70 cu in (11.5 cc) 4-stroke glow

Electric: RimFire .32, 4S 3300 mAh LiPo,

75 A ESC, 13 x 8 E propellerRadio: 4− 5 Channel

Weight: 5 – 5.75 lbs [2270 – 2610 g]

WingLoading: 21– 25 oz/ft2 [ 64 – 76 g/dm2]

Wingspan: 56.5 in [1435mm]

Wing Area: 537in2 [34.6 dm2]

Length: 46 in [1170 mm]

Champaign, Illinois

(217) 398-8970, Ext 5

airsupport@greatplanes.com

GPMA1209

READ THROUGH THIS MANUAL BEFORE STARTING CONSTRUCTION. IT CONTAINS IMPORTANT

INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.

WARRANTYGreat Planes® Model Manufacturing Co. guarantees this

kit to be free from 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, the buyer is

advised to return this kit immediately in new and unused condition to the place of purchase.

To make a warranty claim send the defective part or item to

Hobby Services at the address below:

Hobby Services3002 N. Apollo Dr. Suite 1

Champaign IL 61822 USA

Include a letter stating your name, return shipping address, as

much contact information as possible (daytime telephone

number, fax number, e-mail address), a detailed description of

the problem and a photocopy of the purchase receipt. Upon

receipt of the package the problem will be evaluated as quickly

as possible.

© 2016 Great Planes Model Mfg. A subsidiary of Hobbico,® Inc.

SPECIFICATIONS

INSTRUCTION MANUAL

2

INTRODUCTION

Congratulations and thank you for purchasing the Great

Planes “Zero” Sport Fighter ARF. The Sport Fighter series is

an easy start to scale modeling, but with practical, sport fl ying

characteristics and the durability of an every-day sport fl yer.

For the latest technical updates or manual corrections fi nd

the Sport Fighter Zero ARF page on the Great Planes Model

Manufacturing web site at www.greatplanes.com. If there is

new technical information or changes to this model a “tech

notice” box will appear on the page.

Know Before You Fly

As a new owner of an unmanned aircraft system (UAS), you are responsible for the operation of this vehicle and the safety of those around you. Please contact your local authorities to fi nd out the latest rules and regulations.

In the United States, please visit:

knowbeforeyoufl y.org faa.gov/uas

ADDITIONAL ITEMS REQUIRED

Radio / Servos

A minimum of 4-channels is required to fl y the Zero. The

Tactic TTX650 is recommended because of its simple, fl exible

computer programming and multiple model memory:

❍ Tactic TTX650 6-channel programmable radio

(TACJ2650)

❍ Tactic TR625 6-chanel receiver (TACL0625)

❍ HydriMax 4-cell 2000mAh NiMH receiver pack

(HCAM6321)*

❍ On-off receiver switch (TACM2000)*

*If powering your Zero with a brushless electric motor the BEC

in the ESC may be used to power your receiver and servos, so

no receiver battery or on/off receiver switch will be required.

Servos nowadays are smaller and stronger, so we’ve designed

the servo mounts in the Zero to accommodate mini servos.

Full-size servos may still be used simply by enlarging the

mounts with a hobby knife. Four or 5 servos are required

depending on whether your Zero is electric or glow-powered:

❍ Tactic TSX25 mini digital high-speed 2 ball bearing

servo (TACM0225)

OR❍ Tactic TSX20 mini high-speed 2 ball bearing servo

(TACM0220)

OR❍ Tactic TSX35 standard sport servo (TACM0235)

If mixing the aileron servos through the radio electronically:

❍ (4) 6" [150mm] servo extensions (TACM2092) are

required for the aileron servos.

If mixing the servos with a Y-harness:

❍ (2) 6" [150mm] servo extensions (TACM2092)

and a Y-harness (FUTM4130) are required for the

aileron servos.

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Know Before You Fly . . . . . . . . . . . . . . . . . . . . . . . . . .2ADDITIONAL ITEMS REQUIRED . . . . . . . . . . . . . . . . . .2 Radio / Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Glow Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Other Accessories for a Glow Engine . . . . . . . . . . . . .2 Brushless Electric Motor . . . . . . . . . . . . . . . . . . . . . . .3 LiPo Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . .3ADHESIVES, HARDWARE AND OTHER ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . .3KIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . .3KIT CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4ASSEMBLE THE WING . . . . . . . . . . . . . . . . . . . . . . . . . .5ASSEMBLE THE FUSELAGE. . . . . . . . . . . . . . . . . . . . . .7 Install the Electric Motor . . . . . . . . . . . . . . . . . . . . . . .9

Mount the Glow Engine . . . . . . . . . . . . . . . . . . . . . . .12 Hook Up the Throttle . . . . . . . . . . . . . . . . . . . . . . . . .13 Mount the Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install the Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15PREPARE THE MODEL FOR FLIGHT . . . . . . . . . . . . . .16 Set the Control Throws . . . . . . . . . . . . . . . . . . . . . . .16 Check the C.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Balance the Model Laterally . . . . . . . . . . . . . . . . . . . 17PREFLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine/Motor Safety Precautions . . . . . . . . . . . . . . . 17 Battery Precautions. . . . . . . . . . . . . . . . . . . . . . . . . .19 Range Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20AMA SAFETY CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . .20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Radio Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20FLYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3

Glow Engine

The Zero is suited for a .46 – .55 2-stroke or .70 4-stroke. The

O.S. Max .55AX (OSMG0557) is illustrated in this manual with

a Bisson Pitts-style muffl er (BISG4046).

Other Accessories for a Glow Engine

❍ 1/4" [6.4mm] R/C foam rubber (HCAQ1000)

❍ Great Planes Dead Center Hole Locator (GPMR8130)

❍ 6-32 tap and drill set (DUBR0510)

❍ Suitable propeller for your engine

Brushless Electric Motor

The electric setup for the Zero is straightforward: a Great

Planes ElectriFly RimFire .32 on a 13 x 8 E prop with a minimum

60A ESC powered by a 4S battery in the 3300 mAh – 4000mAh

range*. A Castle Creations Edge Lite 75 was selected and is

illustrated in the instruction manual because it is compact,

easily programmable and features data logging.

❍ 42-50-800 RimFire .32 (GPMG4700)

❍ APC 13 x 8 thin E prop (APCQ3080)

❍ Castle Creations Edge Lite 75 (CSEM1200)

❍ FlightPower 4S 3300 mAh 25C (FPWP2334)

OR❍ FlightPower 4S 4000 mAh 25C (FPWP2404)

❍ 3/16" heat shrink tubing (GPMM1056)

❍ T-style Star connector (HCAM4001)

* Other propeller options are noted on page 19.

LiPo Battery Charger

To charge a 4S 4000mAh LiPo at 1C, a charger capable of

at least 70 watts is required (4S x 4.2V/cell = 16.8V x 4A =

67 watts). The Triton2 EQ is more than enough charger with

100 W output AC and 120 W output DC (GPMM3156).

ADHESIVES, HARDWARE AND

OTHER ACCESSORIES

Other than common hobby tools here is a list of the rest of

the items required:

❍ 30-minute epoxy (GPMR6043)

❍ Epoxy brushes (GPMR8060)

❍ Mixing cups (GPMR8056)

❍ Mixing sticks (GPMR8055)

❍ Threadlocker thread locking cement (GPMR6060)

❍ Thin CA (GPMR6001)

❍ Medium CA (GPMR6007)

❍ CA applicator tips (HCAR3780)

❍ Optional: Scale Military Pilot (GPMQ9117)

A Robart Super Stand II (ROBP1402) is also indispensable

for working on your Zero.

A covering iron with a cover sock may be required for

tightening and re bonding the covering to the model that may

have loosened between the time the plane was manufactured

and the time the model was removed from the box. The 21st

Century iron is preferred because of its long cord, contoured

shoe and precisely adjustable temperature range:

❍ Coverite 21st Century Sealing Iron (COVR2700)

❍ Coverite 21st Century Cover Sock (COVR2702)

KIT INSPECTION

Before starting to build, take an inventory of this kit to make

sure it is complete, and inspect the parts to make sure

they are of acceptable quality. If any parts are missing or

are not of acceptable quality, or if you need assistance

with assembly, contact Product Support. When reporting

defective or missing parts, use the part names exactly as

they are written in the Kit Contents list.

Great Planes Product Support3002 N Apollo Drive, Suite 1 Ph: (217) 398-8970, ext. 5

Champaign, IL 61822 Fax: (217) 398-7721

E-mail: airsupport@greatplanes.com

REPLACEMENT PARTS LIST

GPMA5395 Wing

GPMA5396 Fuselage

GPMA5397 Tail Surface Set

GPMA5398 Cowl

GPMA5399 Spinner

GPMA5400 Landing Gear Set

GPMA5401 Gear Covers

GPMA5402 Canopy

GPMA5403 Decals

GPMA5404 EP Motor Mount Parts

GPMA5405 Belly Pan

4

PREPARATIONS

Note: The covering on your Zero requires less heat than you

may be used to if you’re already familiar with iron-on coverings

– too much heat causes seams and edges to draw away from

each other causing wavy, uneven edges or exposed balsa.

❏ 1. Use a covering iron with a cover sock to tighten any

loose covering. Wherever the covering is over wood (especially

on the sheet balsa tail surfaces) press down on the iron to

make sure the covering is thoroughly bonded to the balsa

underneath. The optimum temperature measured on the

surface of the cover sock is about 280F [140C] which requires

a dial setting of about 300F [150C] or “medium” heat on

most covering irons. If the covering blisters up over balsa

and cannot be pressed back down, the iron may be too hot

or you are leaving it in one location for too long—try reducing

the heat or moving the iron a little faster.

❏ 2. Give a generous tug on all control surfaces to check the

hinges. Add thin CA where necessary to any loose hinges.

Residual CA or CA “fog” is removable with a paper towel

square dampened with CA debonder.

❏ 3. If powering

your Zero with a glow

engine, apply a fi lm of

epoxy or CA to edges

of the covering around

the nose and fi rewall

to seal from fuel and

exhaust residue.

KIT CONTENTS

1. Fuselage w/ Canopy Hatch

2. Cowl

3. Engine Mount

4. Wings

5. Horizontal Stab

6. Vertical Stab

7. Belly Pan

8. Main Wheels

9. Wheel Covers

10. Main Landing Gear Wires

11. Hardware

12. Nylon Hardware

13. Wing Joiner

14. Fuel Tank

15. EP Motor Mount Box

16. Tail Gear

17. Velcro Strap

18. Laser-cut Wood Parts

1

2

3

9

4

4

1011

1213

1415

16

17

18

6

7

8

5

5

ASSEMBLE THE WING

❏ 1. Attach a 6"

[150mm] servo

extension to each

aileron servo and

secure with the

included 3" [75mm]

shrink tubing cut

into two 1-1/2"

[40mm] pieces.

Refer to this image while mounting the aileron servos

and hooking up the ailerons.

Do the left wing fi rst…

Cut out

Enlarge the aileron

servo mount as necessary

to fit your servos.

❏ 2. If necessary, enlarge the servo cutout to fi t your servo.

❏ 3. Use the string to pull the aileron servo wire through

the wing (or just guide the servo wires down through the

holes without using the string) and fi t the servo into the

servo openings.

❏ 4. Drill 1/16" [1.6mm] holes for the servo mounting screws

in the wing and for the control horn screws on the aileron

(use care not to drill through the top of the aileron). Mount the

servo and horn, make the pushrod and hook up the aileron

using the hardware shown.

❏ 5. After mounting the aileron horns, remove the screws,

harden the holes with a few drops of thin CA, allow to harden,

and then reinstall the screws.

❏ 6. Hook up the aileron servo in the right wing the same way.

1/8" [ 3 mm]

❏ 7. Use a fl at landing gear strap as a guide to drill 3/32"

[2.4 mm] holes into the landing gear block in the left wing–

angle the straps so the holes will be 1/8" [3mm] from the

edge of the groove.

❏ 8. Mount the main landing gear to the rails with two straps

and four M3 x 10 screws.

6

❏ 9. Use two M2 x 8 machine-thread screws, washers, M2

nuts and a little threadlocker to loosely fasten two hump

straps to the outside of one of the wheel covers.

❏ 10. Fasten the cover to the landing gear wire with two

more screws, washers, nuts and threadlocker and tighten

all the screws.

❏ 11. Mount the other landing gear, wheel and cover to the

right wing the same way.

❏ 12. Lightly wet the threads of four M3 set screws with

threadlocker and mount the main wheels to the main landing

gear wire with a wheel collar on both sides—a 1.5mm

machined hex driver is recommended for securely tightening

the set screws (rather than a stamped “L” hex key wrench).

❏ 13. Glue together both pieces of the plywood wing

joiner—epoxy may be used to provide more working time

for alignment, or CA may be used for faster assembly.

❏ 14. Once the glue on the joiner halves has hardened, test-

fi t the wings together with the joiner and the nylon alignment

pin. Make any adjustments necessary for a good fi t.

7

❏ 15. A few paper towels cut into small squares and denatured

alcohol will be useful for cleaning off excess epoxy during the

next step while gluing the wing halves together.

❏ 16. Apply 30-minute epoxy to all joining surfaces including

the root ribs and the “Joiner Pockets” inside the wings where

the joiner goes. Securely hold the wing halves together with

masking tape and small clamps or clips on the tabs. As you

proceed, use paper towel squares dampened with denatured

alcohol to wipe away excess epoxy.

❏ 17. After the epoxy has hardened remove the clamps

and tape.

ASSEMBLE THE FUSELAGE

❏ 1. Cut and remove the spacer from the slot for the horizontal

stabilizer at the back of the fuselage.

❏ 2. Mount the wing to the fuselage with two 10-24 x 2" nylon

wing bolts (for convenience, you may shorten the wing bolts

by cutting them to a length of 1-1/2" [40 mm]).

8

❏ 3. Test fi t the tail gear wire into the rudder and fi t the vertical

and horizontal stabilizers into the fuselage.

❏ 4. View the model from behind and check the alignment

between the horizontal stabilizer and the wing. If necessary,

adjust the slot in the fuselage to get the stab horizontally

aligned with the wing—in most cases, all that will be required

is a small amount of weight on the high side of the stab.

❏ 5. Remove the stab and fi n from the fuselage. Use

30-minute epoxy to glue the tail gear wire into the rudder

and glue the stab and fi n into the fuselage. Use more paper

towel squares dampened with denatured alcohol to wipe

away residual epoxy. If any weight was required to level the

stab with the wing don’t forget to reposition the weight and

double-check the alignment before the epoxy hardens.

❏ 6. Use the holes in the tail gear bracket as a guide to

drill 1/16" [1.6mm] holes into the bottom of the fuselage for

the mounting screws. Screw three M2.5 x 8 screws into the

holes, remove the screws, add a few drops of thin CA to the

holes, allow to fully harden, then mount the gear bracket to

the fuse with the screws. Mount the tail wheel with a small

collar and a M3 set screw and threadlocker.

❏ 7. Tighten the collar up against the tail gear bracket with

an M3 set screw wetted with threadlocker.

9

❏ 8. Use medium-grit sandpaper to roughen the fl ange on

the belly pan and remove any minute inconsistencies so glue

will adhere. Test-fi t the belly pan to the bottom of the wing

and make any adjustments necessary for a good fi t.

❏ 9. With the belly pan in position, tape one side down to

the wing. Use thin CA dispensed through a fi ne tip to glue the

other side of the belly pan to the wing—little CA is required and

use care not to apply too much CA at the front and back of

the belly pan so excess will not glue the wing to the fuselage.

❏ 10. Remove the tape and glue the other side of the belly

pan to the wing. After the CA has hardened, a paper towel

square dampened with CA debonder may be used to wipe

off any excess CA or CA fog.

❏ 11. Carefully trim the corners of the belly pan that protrude

beyond the fuselage and the wing.

If installing a glow engine skip to Mount the Glow Engine

on page 12.

Install the Electric Motor

❏ 1. Glue together both pieces of the front plate and the

back plate for the EP motor mount box alternating the wood

grain direction of each set. NOTE: These parts may already

be glued together by the factory.

10

❏ 2. Press 4-40 blind nuts into the front plate and glue them

in with CA.

❏ 3. With the blind nuts on the inside of the assembly, glue

all the motor mount box parts together—it’s quick and easy

just to hold the assembly together while gluing it with thin CA.

❏ 4. Glue the triangle stock reinforcements around the front

and back plates—it’s easy to position them with a hobby

blade and glue them down with medium CA.

❏ 5. Drill 1/16" [1.6mm] pilot holes through the “O” marks

in the fi rewall, then enlarge the holes with a 5/32" [4mm] drill.

Insert 6-32 blind nuts into the back of the holes.

❏ 6. Cut the rest of the way through the partially cut air inlet

in the fi rewall and remove the piece.

❏ 7. Mount the motor mount box to the fi rewall with four 6-32

x 3/4" Phillips screws and #6 lock washers and fl at washers

and threadlocker.

11

❏ 8. Assemble the motor and mount it to the motor mount

box with four 4-40 x 1/2" Phillips screws and #4 lock washers

and fl at washers and threadlocker—notice that the motor

wires are positioned on the left side for a smooth connection

to the ESC.

❏ 9. Connect your ESC to the motor and mount the ESC to

the bottom of the motor mount box—for the Castle Creations

Edge Lite 75 ESC we soldered the female bullet connectors

that came with the motor to the three motor wires (protected

with 3/16" heat shrink tubing) and a Star connector to the

battery wires, then mounted the ESC to the box with a piece

of foam rubber and nylon ties.

❏ 10. Power up the ESC and use the transmitter to run

the motor to make sure it turns the correct direction. If the

motor turns the wrong direction swap any two of the three

motor wires.

❏ 11. Glue the two balsa sticks across the back of the

fi rewall so the screws don’t puncture the LiPo battery in the

event of a crash.

❏ 12. Attach the rougher, “hook” side of the included

adhesive-back Velcro® strip to the battery mount plate and

the other, softer “loop” side to your battery.

12

❏ 13. Test-mount your battery with a battery strap made

from the included Velcro strips.

❏ 14. Mount the cowl with four 4-40 x 1/2" screws and #4

washers and lock washers—the two screws in the top go in

through the front of the cowl and the two screws in the bottom

go in from the back inside the fuselage. For safety reasons,

do not mount the propeller until instructed to do so after the

radio has been set up and the control throws have been set.

❏ 15. Cut the covering from the air passage slots in the

bottom of the fuselage.

Skip to Install the Radio on page 15.

Mount the Glow Engine

The instructions illustrate installation of an O.S. Max .55 AX

with a Bisson No. 04046 Pitts-style muffl er. If using a different

engine and/or a different muffl er, slight adjustments may be

required in the way your engine is rotated on the fi rewall,

but as long as you align the four engine mount screws with

the circle inscribed on the fi rewall, the engine will be in the

correct location.

❏ 1. Drill 1/16" [1.6 mm] pilot holes through the “X” marks in

the fi rewall, then enlarge the holes with a 5/32" [4mm] drill. If

using an engine or muffl er other than the O.S. .55AX/Bisson

Pitts-style muffl er, the engine mount may need to be rotated

differently around the circle embossed in the fi rewall. However

you orient your engine, be sure to keep all four engine mount

holes on the circle embossed in the fi rewall so your engine

and mount will be positioned properly.

❏ 2. Insert 6-32 blind nuts into the holes in the back of the

fi rewall.

❏ 3. Cut the “spreader bar” from both halves of the included

engine mount and trim off any remaining material so they fi t

together well.

❏ 4. Temporarily mount the engine mount with four 6-32 x 1"

screws and lock washers and fl at washers, but don’t tighten

the screws all the way yet.

13

❏ 5. Place the back plate of the spinner on the engine and

position the engine on the mount so the back plate will be 5"

[125 mm] from the fi rewall. Tighten the engine mount screws

and hold the engine in place with a clamp. Use a Great Planes

Dead-Center Hole Locator or similar tool to mark the engine

mount bolt hole locations onto the mount.

❏ 6. Remove the engine and drill #36 (.106" [2.7mm]) holes at

the marks, then tap 6-32 threads into the holes—if available,

a drill press is preferred for drilling the holes and the tap may

be chucked in a hand drill to tap the threads.

❏ 7. Mount the engine to the mount with four 6-32 x 3/4"

Phillips screws and #6 lock washers.

Hook Up the Throttle

❏ 1. If necessary, enlarge the cutout in the throttle servo

tray to fi t your servo. Determine which side of the fuselage

works best for the throttle servo to align with the arm on the

carburetor, then glue the parts together to fi t that side.

❏ 2. Mount the throttle servo in the servo tray.

❏ 3. Glue the throttle servo tray into the side of the fuselage

that aligns with the carb arm.

❏ 4. Use the pattern on page 20 to make the throttle pushrod

from the 2-56 x 19-3/4” [500 mm] pushrod.

14

❏ 5. Install the throttle pushrod and connect it to the throttle

servo. Bend the front of the pushrod as necessary to connect

to the screw-lock connector on the carburetor arm with a

screw-lock retainer.

❏ 6. Make a fuel tank strap by cutting one of the Velcro

strips to a length of 6" [150mm] and the other strip to 7-1/2"

[190mm]. Hook the straps together overlapping 2" [50mm].

❏ 7. Install the fuel tank with a 2-1/2" x 5" [60 x 125mm]

sheet of foam rubber on top of the fuel tank plate and secure

the tank with the strap.

Mount the Cowl

The following instructions illustrate how to mount the cowl

and cut the muffl er exhaust holes with the included template

for the O.S. Max .55AX with the Bisson muffl er. If using a

different engine and/or muffl er, mount the muffl er to the

engine fi rst, then cut the cowl as necessary for the muffl er

and the exhaust opening.

A No. 569 or 570 Dremel grout removal bit and a

sanding drum are indispensable for accurately cutting

a cowl. Always wear eye and breathing protection

when cutting fiberglass.

❏ 1. Mount the cowl with four 4-40 x 1/2" [12mm] screws and

#4 washers and lock washers—the two top cowl mounting

screws go into the front of the cowl ring and the bottom two

screws go in from the back inside the fuselage.

15

❏ 2. Cut the muffl er cutout template for the Bisson muffl er

from the back of the manual and tape it into position as shown.

Mark the exhaust tube holes on the cowl, remove the cowl

and cut the holes.

❏ 3. Use a reinforced cutoff wheel (or other suitable tool

for cutting aluminum) to cut the exhaust tubes to a length

of 1-3/4" [45mm]. This length will allow the exhaust tubes

to protrude from the cowl far enough to direct most of the

exhaust away from the bottom of the model, but still allow

the cowl to fi t over the tubes. Deburr the ends of the tube

with a metal fi le or sandpaper and a hobby knife.

❏ 4. Use compressed air or warm, soapy water to thoroughly

clean all metal fi lings from the muffl er. Mount the muffl er to

the engine and mount the cowl to the fuselage enlarging the

exhaust cutouts as necessary to install the cowl over the

muffl er tubes.

❏ 5. Cut any more holes in the cowl necessary for the needle

valve, fueling line, glow plug igniter, etc.

❏ 6. Once all the holes are cut in the cowl, smooth any

rough edges and remove loose fi bers with 320-grit, then

400-grit sandpaper.

Install the Radio

❏ 1. Make the elevator and rudder pushrods as shown.

❏ 2. Install the pushrods into the guide tubes in the fuselage.

Drill 1/16" [1.6mm] holes into the rudder and through the

elevator for the horn screws. Mount the rudder horn with

two M2 x 10 screws and mount the elevator horn with two

M2 x 12 machine-thread screws and the horn mount plate.

16

❏ 3. Remove the screws from the rudder horn, harden the

screw holes with a few drops of thin CA, allow to harden,

then reinstall the screws.

❏ 4. If necessary, enlarge the cutout in the servo tray to

fi t your servos, then install the servos in the tray but don’t

screw them down yet. Center the rudder and elevator and

the servos. Mark the pushrods where they cross the holes

in the servo arms.

1/16" [1.5 mm]

Servo Arm

❏ 5. Disconnect the clevises from the horns and remove the

pushrods from the fuselage. Make a 90-degree bend in each

wire at the marks. Fit each pushrod to a servo arm, install

a 90-degree pushrod keeper, cut off the excess wire, then

reinstall and connect the pushrods (this will require temporary

removal of the clevises).

❏ 6. If using a receiver battery for a glow engine, the battery

may be mounted on top of the optional battery tray. The tray is

mounted with four M2.5 x 8 washer-head Phillips wood screws.

❏ 7. Apply the decals – the best way is to peel a decal from

the sheet, spray the back with window cleaner, position the

decal, then squeegee out the window cleaner with a small

balsa sheet. This technique allows for precise positioning

and eliminates air bubbles.

Install a Pilot (Optional)

A Great Planes 1/7-scale painted military pilot was used

(GPMQ9117).

❏ 1. Cut and remove the pilot base from the cockpit fl oor.

Place your pilot onto the base and test-fi t inside the cockpit

to make sure he fi ts. Trim the pilot as necessary.

❏ 2. Fasten the pilot to the base with CA or screws.

17

❏ 3. Glue strips of

balsa to the base

serving as tabs

for alignment – be

certain the tabs do

not interfere with

the fi t of the canopy

hatch to the fuselage.

❏ 4. Glue the pilot base back onto the cockpit fl oor.

PREPARE THE MODEL FOR FLIGHT

Set the Control Throws

In addition to the C.G., the control throws have a major effect

on how the model fl ies and whether or not your fi rst fl ight will

be successful. Do not skip this important step and make sure

the throws are within the specifi ed range. If necessary, use

programming in your transmitter and/or change the locations

of the pushrods in the servo arms and/or control horns to

adjust the throw.

Use a box or something similar to prop up the fuselage so the

horizontal stabilizer will be level. Check and set the control

throws according to the measurements on the next page:

Note: the throws are measured at the widest part of the

aileron, elevator and rudder.

These are the recommended control surface throws:

ELEVATOR

HIGH

5/8 in. [16mm] 19°

1-3/4 in. [44 mm] 21°

1/2 in. [13 mm] 21°

LOW

3/8 in. [10mm] 11°

1 in. [25mm] 12°

1/4 in. [6mm] 11°

Up & Down

RUDDER

AILERONS

Up & Down

Right & Left

Check the C.G.

Same as the control throws, the C.G. has a great effect on how

the model fl ies. If the C.G. is too far forward the model may

be too stable and unresponsive to control inputs. If the C.G.

is too far aft the model may be too responsive and instable.

❏ 1. The model should be completely ready to fl y with all

components installed (and an empty fuel tank if using a

glow engine).

❏ 2. If building the electric version, install the propeller and

spinner and install the motor battery.

18

75 mm

100 mm

3"

4"

Fuselage sides

The recommended C.G. is 3"− 4" [75 mm −100 mm]

back from the leading edge of the wing where it meets

the fuselage.

❏ 3. Use a Great Planes C.G. Machine to balance the model

according to the measurements specifi ed in the illustration,

or mark the balance range on the top of the wings and lift

it upside-down with your fi ngertips. As long as the model

balances anywhere within the specifi ed range it is acceptable

(but less-experienced pilots should perform fi rst fl ights with

the Zero balanced in the middle or forward half of the range,

slightly nose heavy).

❏ 4. If the Zero doesn’t balance where specifi ed, move the

receiver battery or motor battery or add stick-on lead ballast

to the nose or tail to achieve the correct C.G.

❏ 5. If you’ve made any adjustments by adding ballast or

moving components, check the C.G. again before fl ying.

Balance the Model Laterally

❏ 1. Lift the Zero several times by the propeller shaft and

the tail to see if one wing drops.

❏ 2. If one wing drops consistently, add weight to the opposite

tip by sticking it to the outside or strategically concealing

it inside the balsa tip. An airplane that has been laterally

balanced will track better in fl ight and maintain its heading

better during maneuvers when the plane is climbing.

PREFLIGHT

Engine/Motor Safety Precautions

Failure to follow these safety precautions may result in

severe injury to yourself and others.

● Keep all engine fuel in a safe place, away from high heat,

sparks or fl ames, as fuel is very fl ammable. Do not smoke

near the engine or fuel; and remember that engine exhaust

gives off a great deal of deadly carbon monoxide. Therefore

do not run the engine in a closed room or garage.

● Get help from an experienced pilot when learning to operate

engines.

● Use safety glasses when starting or running engines.

● Do not run the engine in an area of loose gravel or sand;

the propeller may throw such material in your face or eyes.

● Keep your face and body as well as all spectators away

from the plane of rotation of the propeller as you start and

run the engine.

● Keep these items away from the prop: loose clothing, shirt

sleeves, ties, scarfs, long hair or loose objects such as

pencils or screwdrivers that may fall out of shirt or jacket

pockets into the prop.

● Use a “chicken stick” or electric starter to start the engine.

Do not use your fi ngers to fl ip the propeller. Make certain

the glow plug clip or connector is secure so that it will not

pop off or otherwise get into the running propeller.

● Make all engine adjustments from behind the rotating

propeller.

● The engine gets hot! Do not touch it during or right after

operation. Make sure fuel lines are in good condition so

fuel will not leak onto a hot engine, causing a fi re.

● To stop a glow engine, cut off the fuel supply by closing

off the fuel line or following the engine manufacturer’s

recommendations. Do not use hands, fi ngers or any other

body part to try to stop the engine. To stop a gasoline

powered engine an on/off switch should be connected to

the engine coil. Do not throw anything into the propeller

of a running engine.

WARNING: For brushless electric motors, never have the

motor battery connected to the ESC without the transmitter

turned on – after each fl ight (or any time after running the

motor) always disconnect the battery before turning off

the transmitter. And when ready to fl y (or whenever running

the motor for any reason), always turn on the transmitter

fi rst before connecting the motor battery.

Also make certain your failsafe is programmed correctly

so in the event the receiver ever loses signal (or, if you

inadvertently turn off the transmitter before disconnecting

the battery or vice-versa) the motor will not turn. Follow

the instructions that came with your radio control system

to check and set the failsafe.

19

The recommended RimFire .32 is rated for 50 A constant

current and 80 A surge current, so you want to load (prop)

the motor to operate within that range. The closer to 50A the

longer you can fl y full-throttle and the closer to 80 A the less

you can fl y full-throttle until the motor gets too hot.

For starters, an APC 13 x 8 E (on a 4S LiPo) draws about 58A

static and momentary, maximum peaks of about 50– 55 A

in the air, but averages a little less than 20 A with “normal”

throttle use. This is a suitable propeller choice and fl ies the

Zero well—it can be zoomed around boreing holes in the sky,

or cruise at lower throttle settings for more scale-appearing

fl ight and extended air time.

We’ve also fl own the Zero with a 13 x 10E on 4S which peps

up the Zero noticeably. Then, the static current rises to about

68 A with momentary, maximum in-fl ight peaks up to around

70 A and averages around 50 A with normal throttle use. The

13 x 10 E is another suitable propeller, but prudent throttle

management must be used so as not to overheat the motor

and if necessary, it may be a good idea to allow the motor

to cool between fl ights.

Finally, we fl ew the Zero on a 12 x 12 E prop. It produces

about the same numbers as the 13 x 10 E, but the Zero fl ies

a little faster and loses a little thrust.

With all the props, fl ight time depends greatly on how you

use the throttle. Average current draw can be as low as 13

Amps up to as high as 50 Amps if you’re REALLY hard on

the throttle.

In any case, use a fl ight timer initially set to a conservative

time (4 minutes for example). When the timer sounds, land.

Resting (unloaded) voltage should not be below 3.75V/cell

measured with a volt meter after you land. When you charge

the battery note how much capacity it took to recharge

(indicating how much was used for the fl ight). Strive to use

no more than 80% of the battery’s capacity. Adjust your timer

according to the voltage and capacity used for the fl ight.

You can also use the worksheet on page 23 to determine

optimum fl ight times based on your fl ying style and battery

capacity.

CAUTION: Never run the motor on the ground for more

than a few seconds. Otherwise, you may overload the

motor, battery or ESC.

Battery Precautions

Before mounting the motor and setting up the ESC and battery, read the following important battery precautions:

IMPORTANT: If using multiple battery packs that are connected with an adapter, never charge the batteries together through the adapter. Always charge each battery pack separately. Charge the batteries, then read the following precautions on how to connect multiple packs for fl ying the model:

Battery Precautions:

There are two ways to connect multiple battery packs: In Series and in Parallel.

This is a SERIES battery adapter

that connects two batteries in series.

(3-Cell) 3200 mAh

(2-Cell) 3200 mAh

11.1V

7.4V

These are two 3200 mAh batteries (one 11.1V and the

other 7.4 V ). When joined in SERIES, the result will be

a 18.5 V, 3200 mAh battery.

1. Connecting batteries in “Series” means to connect the +’s to the –’s and the –’s to the +’s. This combines the battery’s Voltages, but the capacity remains the same.

This is a PARALLEL battery adapter that

connects two batteries in parallel.

(3-Cell) 1500 mAh

(3-Cell) 1500 mAh

11.1V

11.1V

These two 1500 mAh batteries (both 11.1V) are being

joined in PARALLEL. The result will be one 11.1V,

3000 mAh battery.

2. Connecting batteries in “Parallel” means to connect the +’s to the +’s and the -’s to the -’s. This combines the battery’s capacities, but the Voltage remains the same.

20

General

1) I will not fl y my model aircraft in sanctioned events,

air shows, or model fl ying demonstrations until it has

been proven to be airworthy by having been previously,

successfully fl ight tested.

2) I will not fl y my model aircraft higher than approximately

400 feet within 3 miles of an airport without notifying the

airport operator. I will give right-of-way and avoid fl ying

in the proximity of full-scale aircraft. Where necessary,

an observer shall be utilized to supervise fl ying to avoid

having models fl y in the proximity of full-scale aircraft.

3) Where established, I will abide by the safety rules

for the flying site I use, and I will not willfully and

deliberately fly my models in a careless, reckless

and/or dangerous manner.

5) I will not fl y my model unless it is identifi ed with my name

and address or AMA number, on or in the model. Note:

This does not apply to models while being fl own indoors.

7) I will not operate models with pyrotechnics (any device

that explodes, burns, or propels a projectile of any kind).

Radio Control

1) I will have completed a successful radio equipment ground

check before the fi rst fl ight of a new or repaired model.

2) I will not fl y my model aircraft in the presence of spectators

until I become a qualifi ed fl ier, unless assisted by an

experienced helper.

3) At all fl ying sites a straight or curved line(s) must be

established in front of which all fl ying takes place with the

other side for spectators. Only personnel involved with

fl ying the aircraft are allowed at or in the front of the fl ight

line. Intentional fl ying behind the fl ight line is prohibited.

4) I will operate my model using only radio control

frequencies currently allowed by the Federal

Communications Commission.

5) I will not knowingly operate my model within three miles

of any pre-existing fl ying site except in accordance

with the frequency sharing agreement listed [in the

complete AMA Safety Code].

9) Under no circumstances may a pilot or other person touch

a powered model in fl ight; nor should any part of the

model other than the landing gear, intentionally touch

the ground, except while landing.

FLYING

It’s well-known among scale pilots that a P-47 Thunderbolt

is an excellent scale subject; its generous wing and tail area

and long tail moment contribute to a sound model airplane

design and it shows in the air. Unless the plane is improperly

designed, heavily built or underpowered any P-47 is easy to fl y.

The Zero is the same way! In addition to being easy to fl y, the

Zero is also quite a “true” fl ying model with minimal coupling or

adverse yaw problems—almost like a pattern plane! This Zero

PARALLEL

adapter

(2-Cell)

(3-Cell)

11.1V

7.4V

PARALLEL

ter

(3

NEVER connect battery packs with different Voltages in Parallel–only combine in Series. Otherwise, the batteries will try to “equalize” with the larger one trying to “charge” the smaller one, thus causing heat and likely a fi re.

(3-Cell) 3200 mAh

11.1V

(3-Cell) 1250 mAh

11.1V

SERIES

adapter

Ah

SERIES

ter

Also NEVER connect battery packs with different ca-pacities in Series or in Parallel.

Range Check

Don’t forget to perform your usual ground range checks as

written in the instruction manual that came with your radio

system to be certain it is operating correctly.

AMA SAFETY CODE

Read and abide by the following excerpts from the Academy

of Model Aeronautics Safety Code. For the complete Safety

Code refer to Model Aviation magazine, the AMA web site

or the Code that came with your AMA license.

21

Other than that, the Zero exhibits no unexpected tendencies.

Because it is a slightly “draggier” type of model the Zero does

benefi t from a few “clicks” of throttle on fi nal approach all the

way until touchdown just to keep a little wind blasting over

the elevator. Even with a little throttle the Zero will still bleed

speed and establish a nose-down attitude until touchdown.

Have a ball! But always stay in control and fl y in a safe manner.

GOOD LUCK AND GREAT FLYING!

does behave differently to different C.G. locations. Balanced

nearer the forward end of the C.G. range the Zero seems to

ground handle a little better once the wheels touch the ground

during a landing and is slightly less likely to bounce back into

the air. The takeoff rollout is also a little easier—once the tail

rises the Zero can be steered all the way down the runway

as long as you please until you bump the elevator to make

the plane rise into the air. Balanced nearer the aft end of the

C.G. range the Zero feels a little more “nimble” and is more

agreeable to being “thrashed” around in the air. But at an aft

C.G. you’ll notice the Zero may fl oat a little on landing. For

windier days a farther forward C.G. may be preferred.

Throttle pushrod

(For O.S. Max .55AX)

To throttle

servo

Exhaust tube template for O.S. Max

.55AX with Bisson Pitts-style muffler

I.D. Tag

This model belongs to:

Name

Address

City, State, Zip

Phone Number

AMA Number

22

Notes:

FORMULASA

12345678910

B C D E F GB / A D x .8 E / C B/1000 / (A/60)

Flight Time(.10 ths )

RechargeCapacity mAh/minute

BatteryCapacity

Target Capacityto Use in Flight

RecommendedFlight Time

Avg. In-FlightCurrent

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GPMA1209Entire Contents © 2016 Great Planes Model Mfg. A subsidiary of Hobbico, Inc.

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