sak-ace100 - stevensaero.com · hardware bag: ☐ 1 heat shrink tube, 1 1/2 in. x 1/16 in. ☐ 1...

Wing Span: 24 inches | Wing Area: 100 square inches | Average Flying Weight: 2.25 ounces

Build Instructions - Version 1.18 (revised 03.30.2017)

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100

Build Instructions

Ace (100) - Build Instructions © 2017 Stevens AeroModel, all rights reserved. Page �2

WARRANTY

Stevens AeroModel 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 Stevens AeroModel’s liability exceed the original cost of the purchased kit. Further, Stevens AeroModel reserves the right to change or modify this warranty without notice.

LIABILITY RELEASE

In that Stevens AeroModel 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 use by the user. 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.

THIS PRODUCT IS NOT INTENDED FOR CHILDREN 12 YEARS OF AGE OR YOUNGER.

WARNING: This product may contain chemicals known to the state of California to cause cancer and/or birth defects or other reproductive harm.

PRODUCT SUPPORT

This product has been engineered to function properly and perform as advertised, with the suggested power system and supporting electronics as outlined within this product manual. Product support cannot be provided, nor can Stevens AeroModel assist in determining the suitability or use of electronics, hardware, or power systems not explicitly recommended by Stevens AeroModel.

For product assembly support, replacement parts, hardware, and electronics to complete this model, please contact Stevens AeroModel at www.stevensaero.com.

Stevens AeroModel 26405 Judge Orr Rd., Colorado Springs, CO 80808 USA 719-387-4187 www.stevensaero.com

http://www.stevensaero.com




Build Instructions

Ace (100) - Kit Inventory☐ Laser-cut wood, 10 sheets (See Sheet Wood Inventory, page 5) ☐ Illustrated Build Instructions ☐ Plan Set, 2 sheets, 11 in. x 17 in.

Taped to back of wood brick: ☐ 1 Landing gear, wire, .032 in. x 12 in. ☐ 2 Push rods, wire, .015 in. x 18 in.

Hardware Bag: ☐ 1 Heat shrink tube, 1 1/2 in. x 1/16 in. ☐ 1 Delrin receiver clip ☐ 1 Pair plastic wheels (SIGSH450)

Background

The Ace (100) is a pint-sized package, bursting at the seams with nostalgic charm. This compact 100 square-inch radio control model is designed to use ParkZone PKZ3352 ultra-micro electronics. The Ace can be flown indoors, at the local gymnasium, or hop from thermal-to-thermal outdoors in late evening lift.

The nostalgic lines of the Ace are presented here with a strong nod to Henry Struck and his 1940’s vintage New Ruler and American Ace free flight designs. The Ace design was directly inspired by this iconic model, while reminiscent of those bygone years, our kit offers a modern design that builds trouble-free and quickly, thanks to innovative design processes pioneered by Stevens AeroModel.


Build Instructions

Suggested Items to Complete this ModelMany of the suggested items listed below are available at your local hobby shop. For your convenience, Stevens AeroModel stocks all the power system components and most of the building supplies required to complete this kit. If you have difficulties sourcing any of these items locally, please visit our website, stevensaero.com to purchase the items necessary to complete your model.

Required Electronics

☐ RC transmitter with at least 3 channels ☐ Receiver/ESC/Servo brick (PKZ3352 or SPMAR6410)* ☐ Motor/Gearbox (PKZ3624) ☐ Propeller, 130mm x 70mm (EFL9051) ☐ LiPo battery, 120 - 160 mAh 3.7V *SPMAR6410 may be used with computer radio.

Covering Film Requirements While any high-quality covering film may be used to finish this model, superior results will be achieved by using genuine AeroLITE brand covering film, available exclusively from Stevens AeroModel. The lower working temperature and light weight of AeroLITE are especially desirable for this type of model.

AeroLITE is one-third the weight of typical model covering films, and will present a significant weight savings when applied to this model.

☐ 2-3 PatchPaks AeroLITE base color ☐ 1 - PatchPak AeroLITE trim color or 1 roll AeroTRIMTM (pressure-sensitive adhesive trim) ☐ 1 - Optional black vinyl markings set to complete the model as illustrated (SAP-ACE100/DECAL)

Sealing Bare Wood

While not required, it is suggested that a high-quality clear lacquer be used to protect and seal any unfinished wood. One single light coat of clear lacquer should be sufficient to protect the model from moisture, without adding significantly to the model’s final flying weight. Many parts of this model may be colored using a lacquer-based spray paint. Listed below are some of the products we have used on our models. Please feel free to use whatever products you prefer.

☐ DEFT clear lacquer-based sealant (available at most hardware stores) ☐ Design Master Color Tool, lacquer-based spray paint (available at most arts and crafts stores)


Required Building Supplies and Tools

☐ CA glue, medium, 1/4 oz (PAAPT04) ☐ CA glue, thin, 1/4 oz (PAAPT10) ☐ CA glue applicator tips (PAAPT21) ☐ CA glue accelerator (PAAPT15) ☐ Hobby knife with supply of #11 blades ☐ Sanding block with 120 and 240 grit paper

Building Supplies and Tools

☐ Covering iron and heat gun ☐ Needle nose pliers, small ☐ Clear tape, 1/2 in. (DUB916) ☐ Velcro for mounting battery (PKZ1039) ☐ Masking tape (low-tack blue painters’ tape) ☐ AeroLITETM covering film

Optional Building Supplies and Tools

☐ Balsa filler (HCAR3401) ☐ Modeling clay (ballast) ☐ CA glue de-bonder (PAAPT16)

☐ Required Building Supplies ☐☐ Clear lacquer-based sealant (DEFT®) ☐ Lacquer-based spray paint (Design

Master®)

Build Instructions

Sheet Wood Inventory (1 of 1)


Build Instructions

Builder’s Notes


Build Instructions

General Assembly InstructionsThank you for purchasing the Ace 100 from Stevens AeroModel.

This model has been developed and manufactured using state-of-the-art CAD/CAM systems. Our kits feature a unique interlocking construction process, that when compared to traditional building methods, saves countless hours of measuring, cutting, sanding, and fitting. We are certain that you’ll find our kit to offer a truly exceptional build experience. As this kit is recommended for the novice model builder and pilot, we invite beginners who have purchased this kit to seek the help of an experienced builder and pilot. If at any time during the assembly of this kit, should you run across a term or technique that is foreign to you, please contact our staff with your questions.

IMPORTANT!Please READ and RE-READ these build instructions along with any other included documentation before starting your build and/or contacting our staff for builder support.

Pre-SandingDO NOT SKIP THIS STEP. Before removing any parts from the laser-cut sheet wood, use a sanding block loaded with 120 - 240 grit sandpaper and lightly sand the back side of each wood sheet. This step removes any residue produced as a result of the laser cutting process. We have found that most stock wood sizes run several thousandths of an inch oversized. This step also slightly reduces the thickness of each sheet of wood. Leave all parts in the sheet wood until required for assembly.

Protecting Your Work SurfaceUse the poly tube that this kit was shipped in as a nonstick barrier between your work surface and the product assembly.

Bonding the AssemblyThis product’s tabs and notches interlock like a 3D puzzle. We strongly suggest that when fitting parts, you dry fit (use no glue) the parts together first. It is advised to work 1 - 2 steps ahead in the instructions, using this dry-fit technique. This allows the opportunity to inspect the fit and location of assembled components, and shows the benefits of our construction technique. As each successive part is added, it contributes to pulling the entire assembly square. Once you arrive at the end of a major assembly sequence, square your work on a flat work surface and bond the dry fit joints with glue. Using the dry-fit process, you’ll be able to recover from a minor build mistake and will ultimately end up with a square and true assembly. Unless otherwise noted in the instructions, we find it easier to “tack glue” parts (temporarily bonding parts in assemblies, using a small dot of glue). When using medium CA glue, apply with a fine-tip CA glue applicator. Never bond painted or covered assemblies with CA, as it can destroy the finish of a beautifully prepared model.

Never Force the Fit!This is a precision laser-cut kit. Our lasers cut to within 5 thousandths of an inch in accuracy. Yet the wood stock supplied to us by the mill may vary in thickness by up to 20 thousandths. This variance in the wood stock can cause some tabs and notches to fit very tightly. With this in mind, consider lightly sanding or lightly pinching a tight-fitting tab, rather than forcing the parts together. You will break fewer parts in assembly, and end up with a square and true airframe.

Manual Updates

Please check our website for updates to these instructions before starting the build. To obtain downloads and updates to this model aircraft kit, please visit the product page at stevensaero.com


Build Instructions

FuselageFuselage parts are designated with the letter “F” followed by a number. Parts have been numbered so that the fuselage assembly follows a sequential order: F1 to F32.

Note: When initially bonding parts, use a single, small drop of medium CA glue, applied sparingly with a CA glue applicator tip to “tack glue” the part in place. Should you commit an error in assembly, it will be easier to recover from the mistake and remove or correct the part in error, if you do not soak the assembly with glue after each step! This method of assembly will allow our interlocking design to do its job. As each successive part is installed within the fuselage, it will help pull the entire structure square and true. When a major assembly is completed, revisit all joints and bond completely. Do not use excessive amounts of glue, as this only adds weight to the model.

1. Central Crutch - Lay F1a (sheet 01/10, 1/16 in. balsa) on the work surface with the etched side facing up. Fit and bond F1b (sheet 01/10, 1/16 in. balsa) to the rear of F1a.

2. Pylon Pocket: Lay both F2’s (sheet 02/10, 1/16 in. balsa) on the work surface with the etched sides facing up. Fit and bond one F3 (sheet 01/10, 1/16 in. balsa) to the slot in the center of each F2.

3. Fit the F2/F3 assemblies to the slots in the front portion of F1, oriented so that the arrows at the front of each F2 point to the front of F1. Do not bond!

4. Slide F4 (sheet 03/10, 1/16 in. balsa) between the F2’s oriented so that the arrow at the front of F4 points toward the front of F1/F2. Tip: Use a wide length of 1/16 in. thick balsa, as a push stick, to reach within the saddle cut at F4 and assist in seating this part between F2 and flush with F1. Do not bond!

5. Fit former F5 (sheet 01/10, 1/16 in. balsa) to the slots in F1 at the rear of the pylon pocket, and to the tabs at the rear of F2/F4.

6. Fit former F6 (sheet 02/10, 1/16 in. balsa) to the front of the assembly. Bond all parts with CA. Make sure that no glue enters the pylon pocket itself!

7. Turn the assembly up side down. Fit and tack glue former F7 (sheet 02/10, 1/16 in. balsa) to the slots in F1 immediately below former F5.


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Build Instructions


Step 1

Step 2

Step 3

Step 4 Step 7

Step 6

Step 5

Step 4 Cont.

F1a

Bottom View

F1b

F2

F1

F4

Flush

F5

F6

F7

F2

F3

F3

F2

F2

Flush

Rear View F2

F1

Top

F1

Front

Build Instructions

Fuselage (continued)

8. Receiver Tray: Lay F8 (sheet 03/10, 1/16 in. balsa) on the work surface with the etched side facing up. Fit the nylon receiver clip found in your hardware bag to F9 and F10, then fit and bond the receiver tray to the four slots in the middle of F8. Orient the tray so that the long arm of the clip is toward the front (tapered end) of F8.

9. Turn the crutch assembly up side down and fit F8 to the bottom of formers F6 and F7, oriented so that the receiver tray is on the bottom of the model.

10. Turn the assembly right side up. Fit and tack glue former F11 (sheet 02/10, 1/16 in. balsa) to the slots in F8 forward of former F6.

11. Fit and bond the nose spine F12 (sheet 03/10, 1/16 in. balsa) to formers F6 and F11, oriented so that the long tab at one end of F12 points forward.

12. Motor Mount - Lay the motor mount plate F13 (sheet 09/10, 1/32 in. ply) on the work surface with the side etched ‘Top’ facing up. fit and bond two F14’s (sheet 09/10, 1/32 in. ply) to the top of F13.

13. Slide former F15 (sheet 10/10, 1/16 in. ply) onto the long tabs on the front of the two F14’s, and the short tabs on the front of F13.

14. Fit the motor mount assembly to the long tab at the front of F12, and the short tabs at the front of F8. The tab at the rear of F13 will fit in the recess in the top of the opening in former F11. Bond with CA.

15. Fuselage Sides - Assemble the fuselage sides by laying F16a (sheet 01/10, 1/16 in. balsa) on the work surface, then fitting and bonding F16b and F16c (sheet 01/10, 1/16 in. balsa) in place, using CA.


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Build Instructions


Step 8

Step 9

Step 10

Step 11 Step 15

Step 14

Step 13

Step 12

F9

Bottom View

F8

F11

F12

F13 Top

F15

Recess

F16a

F16b

F8F10

Long Arm

F7

F6

Receiver Tray

F6

F11

F6

F14

F14

F16c

Top View

F15F12

F11

F13

F14

F14

Build Instructions


16. Fit a fuselage side to each side of the front of the central crutch. Tack glue the fuselage sides to the motor mount F13, the front portion of F8, and formers F6, F11, and F15.

17. Pull the sides together and tack glue to F1, the rear portion of F8, and formers F6 and F7.

18. Turn the assembly up side down and fit former F17 Sheet 02/10, 1/16 in. balsa) to the slots in crosspiece F1b. Pull the sides together, and bond to the rest of F1 and former F17.

19. Fit the stabilizer saddle F18 (sheet 01/10, 1/16 in. balsa) to the rear of the fuselage sides, directly behind F1. Square the assembly on a flat surface, and bond all parts together with CA.

20. Landing Gear Pocket - Turn the assembly up side down. Fit part F19 (sheet 09/10, 1/32 in. ply) into the angled notches in the fuselage sides, and the pair of slots in F8. The notches in the fuselage sides are oversized to accommodate the other parts of the landing gear pocket. F19 will occupy the front portion of the notches. Do not bond.

21. Fit F20 (sheet 09/10, 1/32 in. ply) in the same notches in the fuselage side, flush against the rear of F19. Do not bond.

22. Fit F21 (sheet 09/10, 1/32 in. ply) in the same notches, and the single slot in F8, immediately behind F20. Make sure that all three parts are fully seated, then bond them together and to the fuselage assembly with CA. Make sure that no glue enters the landing gear pocket.

23. Fuselage Bottom - Lay F22a (sheet 03/10, 1/16 in. balsa) on the work surface, then fit and bond F22b and F22c (sheet 02/10, 1/16 in. balsa) in place using CA.


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Build Instructions


Step 16

Step 17

Step 18

Step 19 Step 23

Step 22

Step 21

Step 20

F16

Bottom View Bottom View

Bottom View

Bottom View

F16

F17

F18

F19

F20

F21

F22a

F8

F11F6

F15

F22b

F22c

F13

F7

F6 F1

F8

Build Instructions


24. Fit F22 to the bottom of the fuselage assembly. Bond F22 where it meets the fuselage sides, F21 of the landing gear pocket, and formers F7 and F17, with CA.

25. Fit and bond F23 (sheet 01/10, 1/16 in. balsa) to the fuselage bottom, forward of the landing gear pocket.

26. Nose - Slide F24 (sheet 08/10, 1/8 in. balsa) onto the long tabs on F12 and both F14’s until it is flush against the front face of former F15. Bond with CA.

27. Just as in step 26 above, slide F25 and F26a (sheet 08/10, 1/8 in. balsa) onto the tabs, bonding with CA. Remove the tabs on each side of F26a.

28. Position F26b (sheet 08/10, 1/8 in. balsa) over F26a, aligning the edges of part F26b with the edges of part F26a. Bond F26b to F26a, then remove the tabs on F26b.

29. Upper Fuselage - Fit former F27 (sheet 01/10, 1/16 in. balsa) to the two slots just in front of the large opening in the rear of F1.


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Build Instructions


Step 24

Step 24 Cont.

Step 25

Step 26 Step 29

Step 28

Step 27 Cont.

Step 27

F22

Bottom View

Bottom View

Bottom View

Bond

F23

F24

F26a

Remove Tabs

F26b

F27

Bond

Bond

Bond

F25

Remove Tabs

F7

F21

F17

Build Instructions


30. Fit former F28 to (sheet 01/10, 1/16 in. balsa) the single slot in F1 immediately behind former F27. Make sure that both formers are perpendicular to F1, then bond them together and to F1 with CA.

31. Fit and bond former F29 (sheet 01/10, 1/16 in. balsa) to the slots in crosspiece F1b.

32. Fit and bond former F30 (sheet 01/10, 1/16 in. balsa) to the single slot at the front of F18.

33. Fit the front (wide) end of F31 (sheet 03/10, 1/16 in. balsa) to the recess in the top of former F28. Make sure that F31 is parallel to F1 and that F31 does not extend forward of F28 (interfering with the later fitting of the cockpit sheeting over former F27 – see “Step 34”). Bond F31 to F28 – allow time for the glue to cure. Bend F31 down until it rests in the recesses in the top of formers F29 and F30 – bond with CA.

34. Lightly spray one side of the cockpit sheeting F32 (sheet 01/10, 1/16 in. balsa) with glass cleaner and allow it to soak in for a few seconds. Wrap F32 – moist side out – around formers F5 and F27. The notches at the front of F32 will line up with the notches in former F5 and the split end of F32 will come together centered at the top of F27. Hold F32 in place with low tack masking tape until it is completely dry. When F32 is dry, remove the tape and bond it to the fuselage assembly with CA.

35. Using 3/32 in. square strip stock (sheet 05/10) cut and fit two stringers for each side of the turtle deck at the rear of the fuselage. The stringers will fit into the notches on each side of formers F28 and F29, then lie flat on each side of F31 against the front of former F30. Bond with CA.

36. Using 3/32 in. square strip stock (sheet 05/10) cut and fit two stringers for each side of the nose of the model. The stringers will fit in the notches in formers F15, F11, F6, F3, and end in the pockets created by former F5 and the cockpit sheeting F32. Bond with CA.


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Build Instructions


Step 30

Step 31

Step 32

Step 33 Step 36 Cont.

Step 36

Step 35

Step 34

F28

Rear ViewF27

F29

F30

F31

F32

Stringers

Stringers

Stringers

Stringers

Build Instructions


37. Sanding - Using a sanding block loaded with 120/240 grit paper, sand the nose to match the contours shown on the 11x17 detail sheet.

38. Sand the corners off of the rear stringers so that the covering material will lie in a smooth arc. Leave F31 flat. Lightly sand the rest of the fuselage, removing any excess glue and smoothing the joints between parts.

Set the completed fuselage aside until needed in the Covering steps.

Tail Surfaces

39. Build the vertical stabilizer and rudder from parts V1 through V6, and R1 through R5 (sheet 05/10, 3/32 in. balsa), over the plan on the detail sheet, and bond with CA.

40. Lay the rudder on the work surface with the left side facing up and the leading edge aligned with the edge of the work surface. Using a sanding block or sanding stick, sand a 45 degree bevel along the left side of the leading edge of the rudder.

41. Build the horizontal stabilizer and elevator from parts H1 through H5 and E1 through E5 (sheet 07/10, 3/32 in. balsa) over the plan on the detail sheet., and bond with CA.

42. Lay the elevator on the work surface with the etched side facing down, and the leading edge aligned with the edge of the work surface. Using a sanding block or sanding stick, sand a 45 degree bevel along the leading edge of the elevator.

Lightly sand the completed tail surfaces, removing any excess glue and smoothing the joints between parts. Set the surfaces aside until needed in the Covering steps.

Pylon

43. Lay P1a and P1b (sheet 07/10, 3/32 in. balsa) on the work surface with the etched side facing up. Fit P1a to P1b and bond with CA.

44. Position P2 (sheet 09/10, 1/32 in. ply) between the etched lines and the edges of P1. Bond with CA.


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Build Instructions


Step 37

Step 38

Step 39

Step 40 Step 44

Step 43

Step 42

Step 41

45 deg.

P1a

P2

45 deg.

P1bEtched Lines

Build Instructions

Pylon (continued)

45. Turn P1 up side down so that the P2’s are underneath. Fit P3 (sheet 10/10, 1/16 in. ply) into the slots down the center of P1. Make sure that P3 is perpendicular to P1, then bond with CA.

46. Assemble the pylon sides from parts P4a and P4b (sheet 07/10, 3/32 in. balsa) and bond with CA.

47. Fit the completed P4’s to each side of the pylon, oriented so that the arrow at the front of the P4’s points in the same direction as the arrow at the front of P3. Bond with CA.

Sand the front and rear of the P4’s to round into the front and rear of P3. Set the completed pylon aside until needed in the Covering steps.

WingWing parts are designated with the letter “W” followed by a number. Parts have been numbered so that the wing assembly follows a sequential order: W1 to W22.

48. Inner Wing Panels - Fit ribs W2 (sheet 06/10, 3/32 in. balsa), W4 (sheet 06/10, 3/32 in. balsa), and W3 (sheet 04/10, 1/16 in. balsa) to the spar W1 (sheet 03/10, 1/16 in. balsa), with the etched side of the spar facing to the rear of the ribs. Refer to the plan on the detail sheet for the correct location of each rib.

49. Fit one trailing edge W5 (sheet 05/10, 3/32 in. balsa) to each side of the wing panel, with the arrow at the inner end of W5 pointing toward ribs W2. Tack glue W5 to ribs W2, W3, and W4.

50. Fit one W6 (sheet 05/10, 3/32 in. balsa) to the outside of ribs W2, bonding them to the trailing edge, spar, and ribs W2.

51. Fit and tack glue one leading edge web W7 (sheet 06/10, 3/32 in. balsa) to the front of each wing panel, oriented so that the arrow at the inner end of W7 points toward ribs W2.

52. Fit and tack glue the leading edge W8 (sheet 05/10, 3/32 in. balsa) to the front of each W7, oriented so that the arrow at the inner end of W8 points toward the center of the wing.


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Build Instructions


Step 45

Step 46

Step 47

Step 48 Step 52

Step 51

Step 50

Step 49

P3

Bottom View

Bottom View

P4a

W2

W5

W6

W7

W8

P4b

W1 - Etched Side to the Rear

W2 W3W4

W4W3

W2

W2W1

W8

W2

P2’s Underneath

P3

P4P1

Build Instructions

Wing (continued)

53. Fit sub-ribs W9 and W10 (sheet 04/10, 1/16 in. balsa) to the spar and leading edge web. Refer to the plan on the detail sheet for the correct location of each rib.

54. Fit the diagonal braces W11 through W14 (sheet 03/10, 1/16 in. balsa) between the ribs on each wing panel. Refer to the plan on the detail sheet for the correct location of each brace. Hold one wing panel down on a flat surface, and bond all parts of that panel with CA. Repeat for the other panel.

55. Position the trailing edge brace W15 (sheet 09/10, 1/32 in. ply) into the recess in the center of the trailing edge, and bond with CA.

56. Wing Tip Panels - Fit the tip spar W16 (sheet 03/10, 1/16 in. balsa) to rib W4, oriented so that the etched side faces forward. Align the long tabs on the main spar W1 and W16 within the etched lines on each spar. Bond with CA.

57. Fit ribs W17, W18, and W19 (sheet 04/10, 1/16 in. balsa) onto the spar W16. Refer to the plan on the detail sheet for the correct location of each rib.

58. Assemble the wing tip outline from parts W20 and W21 (sheet 05/10, 3/32 in. balsa) and bond with CA.

59. Fit the wing tip outline to the ribs, spar, leading and trailing edges. Bock up the inner panels until the wing tip lies flat one the work surface. Hold the wing tip down, and bond all parts with CA.

60. Fit the wing tip leading edge W22 (sheet 05/10, 3/32 in. balsa) to the front of the ribs. Carefully align the front face of W22 with the front face of W21, then bond them together with CA.


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Build Instructions


Step 53

Step 54

Step 55

Step 56 Step 60

Step 59

Step 58

Step 57

W10

Rear View

W9

W11

W15

W16

W17

W21

W20

W22

W2

W12

W13W14

Etched Lines

W18W19

Build Instructions

Wing (continued)

61. Sanding - Using a sanding block loaded with 120/240 grit paper, round the leading edge of the wing to flow smoothly into the ribs. Taper W22 to flow smoothly into the extreme tip of the wing. Lightly sand the rest of the wing, removing excess glue and smoothing the joints between parts.

Set the completed wing aside until called for in the Covering steps.

Covering

62. Cover your model with a high quality, light weight iron material. We suggest AeroLITE, available from stevensaero.com – A snazzy vinyl decal set is available separately from Stevens AeroModel as well. Leave the bottom of the fuselage uncovered for now - this will allow access to the interior for installing the pushrods. Cover both sides of the wings and tail surfaces. Cover or paint the head rest. Paint the pylon, tail skid, and control horns to match your color scheme.

Push Rods and Receiver

63. Apply a piece of low tack masking tape folded over one end of each .015 in. wire push rod material supplied in your kit.

64. Slit the covering over the exit slots on each side of the fuselage. Beginning with the rudder push-rod, insert the untaped end through the exit slot on the right side of the fuselage. Pass the wire forward, through the hole on the right side of former F17, then crossing over the fuselage centerline to the hole on the left side of former F7, and into the radio compartment.

Repeat this step fro the elevator push rod this time, inserting the push-rod through the exit slot on the left side of the fuselage, the hole on the left side of former F17, and then crossing over the fuselage centerline to the hole on the right side of former F7.


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Build Instructions


Step 61

Step 61 Cont.

Step 62

Step 62 Cont. Step 64 Cont.

Step 64 Cont.

Step 64

Step 63

Tape

Exit Slot

Bottom View

Bottom View

Bottom View

RudderRight Side

F17

Rudder

Elevator

Left Side

Left Side

F7

Build Instructions

Push Rods and Receiver (continued)

65. Refer to the “Push Rod Detail” on the detail sheet, and make a ‘snake’ bend in the un-taped end of the wires protruding into the radio compartment.

66. Connect the snake bends to the middle hole in the servo tabs, and twist until the end of the wire points up, away from the circuit board.

67. Install the receiver by fitting the rear edge of the circuit board into the notch in the short arm of the receiver clip. Press down on the front edge of the board until it snaps under the long arm of the clip.

68. You may now cover the bottom of the fuselage.

Headrest

69. Assemble the headrest from two each, balsa parts HR (sheet 06/10, 3/32 in. balsa). Use a slow setting glue and bond these 3/32 in. thick parts together, carefully matching the HR parts along their outside edges, creating a single 3/16 in. thick headrest. Use a sanding block loaded with 120 or 240 grit paper to round the top of part HR, as indicated on the plan set. Cover or paint the headrest to match your intended trim scheme.

Carefully center the headrest down the middle of the turtle deck. Hold it in place with low tack masking tape, then apply a small bead of medium CA to each side where the headrest meets the fuselage.

Tail Surfaces

70. Position the vertical stabilizer and rudder on the work surface, oriented with the right - bevelled - side facing down. Make sure that there is a 1/64 in. gap between the surfaces, then secure them to the work surface with low tack masking tape. Slit a length of 1/2 in wide clear tape down the center, leaving you with a strip about 1/4 in. wide. Apply this strip over the gap between the surfaces to create a hinge, and trim off the excess tape. Remove the masking tape, and flex the rudder back and forth, checking for free movement. If there is binding of any kind, remove the hinge tape and repeat the hinging process, increasing the gap between the surfaces slightly.

71. Slit the covering over the control horn slot on the right side of the rudder. Press in the control horn R5 oriented so that the hole in the end of the horn is directly over the hinge line. Bond the horn to the rudder with medium CA.

72. Repeat the process outlined in step 70 to hinge the elevator to the horizontal stabilizer. Make sure that the bevelled side of the elevator faces down!


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Build Instructions


Step 65

Step 66

Step 67

Step 68 Step 72

Step 71

Step 70

Step 69

Tape

Bottom View

R5

Bevelled Side Down!

Right Side

Bevelled Side Down!

Tape

Tape

Rudder Servo

Rudder

Elevator

Elevator Servo Middle Hole

Build Instructions

Tail Surfaces (continued)

73. Turn the stabilizer/elevator over so that the bevelled side of the elevator is facing up. Slit the covering over the control horn slot on the lower-left side of the elevator. Press the control horn E6 into the slot, oriented so that the hole in the end of the horn is directly over the hinge line. Bond the horn to the elevator with medium CA.

74. Remove the covering over the slot in the center of the horizontal stabilizer, on both sides of the stabilizer.

75. Fit the tab at the base of the vertical stabilizer through the slot in the horizontal stabilizer, then fit the tab to the slot in F18 at the rear of the fuselage. Make sure that the stabilizers are perpendicular to the sides and top of the fuselage and each other. Run a small bead along each side of the vertical stabilizer where it meets the horizontal stabilizer, and along the bottom of the horizontal stabilizer where it meets the fuselage.

Control Linkages

76. Trim the push rods 1/8 in. short of the control horns. Keep the scraps.

77. Refer to the Push Rod Detail on the detail sheet and make up two ‘Part B’ from the scrap .015 in. wire. Trim the wires to an overall length of 3/4 in.

78. Locate the 1/16 in. heat shrink tube in your hardware bag and cut a length 3/4 in. long. Slide the tubing over two pieces of the scrap .015 in. wire. Shrink the tubing over the wire using a heat gun or warm soldering iron, and allow to cool thoroughly. When cool, cut the tube into two equal lengths of 3/8 in. each.

79. Fit Part B to the control horn and connect it to the push rod with the 3/8 in. piece of pre-shrunk tubing. You may now slide Part B back and forth past the push rod within the tube until the control surface is centered. When you are satisfied that the surface is centered, secure the push rod by applying a small drop of medium CA to each end of the tube.


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Build Instructions


Step 73

Step 74

Step 75

Step 76 Step 79

Step 78 Cont.

Step 78

Step 77

Center

Bottom View

1/8 in.

3/4 in.

3/4 in.

3/8 in.

Left

2 Pieces .015 in. Wire

Heat Shrink Tube

.015 in. Wire

Build Instructions

Pylon

80. Apply a slow setting glue to the sides of the pylon base, then immediately slide it into the slot in the fuselage, oriented so that the front (straight) end of the pylon points forward. Apply a small bead of medium CA on both sides of the pylon where it meets the fuselage.

Landing Gear

81. Bend the landing gear wire over the pattern on the detail sheet using the 12 in. length of .032 in. wire supplied in your kit. Proceed carefully, as accuracy is critical for a proper fit.

82. Mount the supplied wheels onto the wire. Bend the ends of the axles up 90 degrees, and trim off the excess wire.

83. Slit the covering over the landing gear slot, and press the landing gear into the slot, followed by part LG (sheet 09/10, 1/32 in. ply). Make sure that LG is fully seated, flush with the bottom of the fuselage. Wick CA along the landing gear pocket and the points where the wire exits the pocket to secure the landing gear.

84. Slit the covering over the slot at the rear of the fuselage bottom. Press the tail skid TS (sheet 09/10, 1/32 in. ply) into the slot, and bond with medium CA.

Motor Installation

85. Mount the propellor (EFL9051) by twisting it onto the threaded portion of the prop shaft until fully seated.


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Build Instructions


Step 80

Step 81

Step 82

Step 83 Step 86

Step 85

Step 84

Step 83 Cont.

.032 Wire

Bottom View

Bottom View

Bottom View

Bend Up 90 Degrees

LG

Flush

TS

Prop Shaft Underneath Motor

Front

Build Instructions

Motor Installation (continued)

86. Feed the motor lead into the opening in the nose of the model, and down through the hole in F8 right in front of the landing gear. Press the motor - oriented with the prop shaft underneath the motor - into the opening in the nose of the model until it is fully seated. When properly installed, the gears on the motor should be fully recessed within the opening in the nose. Friction should be enough to hold the motor in place, making it easy to remove in case of damage. You may, however, apply a small drop of white glue or medium CA to the front of each mounting tab to further secure the motor (white glue takes longer to cure but makes any future motor removal much easier). Connect the motor lead to the socket at the rear of the circuit board, oriented so that the black wire is nearest the receiver clip.

Wing Mounting

87. Position the wing on the pylon with the leading edge forward. Secure the wing with two of the No. 16 rubber bands supplied in your kit.

Congratulations! Your Stevens AeroModel Ace is complete! Continue to the Setup and Preflight sections to prepare your model for it’s first flight.


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Build Instructions


Step 86 Cont.

Step 86 Cont.

Step 87

Complete

Black Wire

Bottom View

Bottom View

Build Instructions

Setup

DO NOT ATTEMPT FLIGHT IF THE WINGS ARE WARPED. Inspect the wings for any warps that may have occurred when covering the model, or while the model was in storage. Remove all warps before flight. Lack of aileron control on this model will make flying with a warped wing difficult.

Rudder - Center the rudder. Then, set the direction, rate of travel, and dampening (expo) of the control. The rudder servo should be controlled by the aileron channel on your radio, as the rudder on this model also controls the roll of the aircraft. The rudder should follow aileron stick travel, i.e., moving the aileron stick to the right should move the rudder to the right.

Elevator - Center the elevator. Then, set the direction, rate of travel, and dampening (expo) of the control. The elevator will be controlled by the elevator channel on your radio. Moving the elevator stick back should move the elevator up. Moving the elevator stick forward should move the elevator down.

The Ace was designed to be a very docile flyer. We set up our flight controls with fairly minimal throws. With the push rods connected, per the instructions in this manual, set the control throws as follows:

Preflight

It is recommended that you have an experienced pilot assist you with preflighting your new model. Just like having someone proofread something you’ve written, having a second fresh set of eyes inspect your final product is often helpful in avoiding disaster.

While not a thorough preflight check, listed below are some of the major items that you should consider checking when developing your own preflight check list. Get in the habit of always preflighting your models before every flight.

Weight and Balance - Check the balance of your model (C.G., center of gravity). For proper performance, the model should balance 1-1/2 in. behind the leading edge of the wing - approximately under the spar. Mark the balance point under the left and right wing panels with masking tape or a fine tip marker. Use your right and left index fingers to suspend the model from below, at the marked balance points. If the top edge of the fuselage side and horizontal stabilizer appear to hang level, the model is properly balanced and ready to fly. If the nose or tail of the model hang down, move the battery forward and backward to make subtle changes, or add clay ballast to the nose or tail as required to obtain proper balance.

Check Weather - The first flight should be outdoors in zero wind conditions. The Ace can fly in winds up to 5 miles per hour.

Inspect the Airframe - Always check for warps and obvious signs of wear or damage. Do not fly a warped or damaged model.

Inspect Control Surfaces - Always check control surfaces for center, proper direction of travel, rate of throw, secure push rod connections, hinges, and receiver/servo mounting hardware.

Check Wing Attachment Points - Always make sure you inspect for damage and wear. Make sure that the wing and wing struts, if applicable, are properly attached.


Rudder Travel +/- 15 degrees

Elevator Travel +/- 15 degrees

Build Instructions

Preflight (continued)

Inspect Battery - Always use a freshly-charged battery. Never begin a flight with a partially-charged or damaged battery.

Clear Prop - Stay clear of the prop arc, when applying power to the model.

Range Check Radio - Follow the manufacturer’s instructions for performing a radio range check.

Check for Traffic - Proceed to the flight line (with your mentor/instructor if you are a novice pilot) and look for other traffic. If the runway is clear, and no one is in the pattern to land, loudly announce your intentions to take off. Remember, all aircraft on the ground must yield the runway to those landing.

Go Flying - Point the model into the wind (if present) and steadily advance the throttle to full power. Use rudder control to correct track while on the ground. Within several feet, the model should be airborne. Fly the model to a comfortable “1 to 2 mistakes high altitude”, reduce throttle to stop the climb, then trim the model for straight-and-level flight at a comfortable cruise speed. The Ace typically cruises at just over one-half throttle.

Setup for Landing - Clearly announce your intentions to land. Make all landings into the wind, using rudder and elevator controls. Crosswind landings should be avoided until you are comfortable with the model’s in-flight behavior.

Congratulations!

Once you’ve completed your first flights, you will have noticed that the Stevens AeroModel Ace is a very stable model airplane. When built straight, and trimmed for level flight, it should readily return to “wings level” from any attitude. When flying, we never miss an opportunity to allow an onlooker to get a little “stick-time”.

If your first flight was a bit more exciting than you would have liked, and you are having problems with erratic flight performance, please inspect your airframe and equipment for damage, improper installation, and/or twists and warps. Check to make sure that the model is properly balanced. Moving the C.G. forward slightly can also improve flight performance. The most common mistake modelers make is to try to fly with a warped or twisted wing. Please make certain that your wings are straight and true before you fly.

At Stevens AeroModel, we are committed to improving your building and flying experience. We are constantly refining our processes, designs, and manuals to reflect customer feedback. You may correspond with the Stevens AeroModel staff at:

email: [email protected] Phone: 719-387-4187


mailto:[email protected]

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