'_

Diam.eter 4

Hole

ASSEMBLY INSTRUCTIONS FOR THE

SUPER TWO SEATER

All Bolls

And Nuls Are Aircraft Grode

BOLT

BOLT CHART
I. D. I. D.
No. Description No. Descriptton
CD AN 4- 05 A @ AN 4 - 32 A
® AN 4- 06 A @ AN 4 - 33
® AN 4- 07 @ AN 4·- 33 A
@ AN 4- 10 6 AN 4 - 34
® AN 4- 10 A @ AN 4 - 34 A
® AN 4- HA @ AN 4 - 35
0 AN 4- 12 A @ AN 4- 35 A
® AN 4- 13 .A @ AN 4- 36
® AN 4- 14 A @ AN 4- 36 A
@) AN 4- 15 A ® AN 4 -37
® AN 4- 16 @ AN 4 - 37 A
@ AN 4- 16 A @ AN 4 - 40
@ AN 4- 17 A @ AN 4 - 40 A
@) AN 4- 20 A @ AN 4- 4.1
@) AN 4- 21A ® .AN 4 - 42 A
@ AN 4- 22 A @ AN 4 - 45 A
@ AN 4- 23 A @ AN 4 - 4,6 A
@ AN 4- 24 A @ AN 4 - 50
@ AN 4- 25 A @ AN 4 - 50 A
@ AN 4- 25 @ AN 4 - 51 A
® AN 4 - .26 A @ AN 4- 53 A
@ AN 4- 27 A. @ AN 4 - 54 A
@ AN 4- 30 @ AN 5- 16 A
@ AN 4- 30 A @ AN5 - 40A
@ AN 4- 32 @ AN 5- 44 A GENERAL NOTES:

BE CAREFUL NOT TO OVERTIGHTEN BOLTS OR CRUSH TUBING.

Where two tubes bolt together, use a plastic washer to minimize scuffing under vibration. (See Diagram Below)

At least land 1/2 threads should show beyond the plastic insert in the Nylock nuts to be sure of adequate safety action.

Nylock nuts may be re-used as long cs they are to hard to turn by hand. Bolts Should always as a rule be installed front to back, or nuts on bottom, so they want fall out. (See Diagram Below)

Bolts are identified on the drawings with a small circle and number inside. These numbered circles also show the direction of the bolt. The bolt head will be on the side of the circle. (See Diagram Below)

Use the bolt chert to find the bolt size needed.

All Bolts called for will hove either a 1/4" or 5/16" Nylock nut installed with it.

Follow Numbers To Left Of Captions Near Dinqrums For Sequence Of Assembly.

I. D .. Number

READ AND STUDY THIS PAGE BEFORE ASSEMBLING ANY PARTS

Bolt Head

Plastic Washer

o

17

Plastic Washer

ylock Nu1

Prepared 8 Drawn by Bill Boland

Nose Strut Bracket

WING CONNECTING BRACKETS

Thrust Spar And Trailing Edge Bracket Are The Same

PAGE I

Two Hole Saddle Block

Bevel This Side

Wing Attaching Bracket ----

Wing .ttachlng Bracket

Two Hole Saddle Block

(FRONT I

Engine Mount See Engine Mount Assembly Page 2

I

:3 2" Nose- Strut

Attaching Bracket

Plastic Wushers Between Tubes

Thrust Spar Bracket

Plastic Washers Between Tubes

•

Fuel Tank

Must Be Assembled Inside Fin Sail

Stabilizer Strut----

Plastic Cover

On Threaded Stock

Sub Fin Braces

~., Fine Thread Threaded Stock

SUB FIN ROD ASSEMBLY

Rear View Of Plane

Use Lock-Tight On All Nuts

ASSEMBLY INSTRUCTIONS

I. Start Assembly By Sliding Seat Brackets And Seat Belts On To Main Axle As Shown.

2. Bolt Axle And Center Fuselage Braces Toqether With Main Axle To

Fuselage Brackets (See DETAIL "A").

3. Attach Fuselage Boom To Center Breees As Shown In The Diagram.

4. Attach The Rest Of The Braces As Shown In The Diagram.

5, Attach All Brockets, Engine Mount And FUi!'1 T<mk To The Fuselage Boom. 6, Attach Nose Strut To Nose Strut Bracket.

7. Attach Lower Seat Tubes As Shown In Tile Diagram.

S. Install Main Wheels As Shown. Wing Strut Tangs Hold Bearing. Wheel And Washer

On Axle With Bolt 48.

9. Install The Nose Fork With Steering Bar And Fender As Shown.

10. _toll Nose Wheel As Shown,

II. Attach Throttle Control As Shown.

Steering Bar

See Detail "A"

34· Bent ~wlng Strllt Tong

@ ~ 10· Bent

[, d---W1ng Sind Tang

Large Steel Washer

Rear Fuselage __ -2 .... Braces

Center Fuselage Braces

Use

Heavy Duty .. f/---[,.-- Grease

Main Axle To Fuselage Bracke

FUSELAGE

ASSEMBLY

DETAIL "A"

Prepared 8 Drawn by Bill Boland

".

PAGE 2

Bolt Back Of Plywood BoUom To Axle Loosely.

Then Slip Seat Bottom Over Front Of Plywood. Back Of Seat Bottom Can Be Pulled 'Up

To Tighten Bolts.

Pull Flap Around AIde And Seal Velcro. Then Insert

Sheet Metal Screws.

Rear Seat Fu.selage Brace

Leading Wing Bracket Bevel Towards Back

Engine Mount Brockel

Upholstered Seat Bottom -- ......

~~~

Fuselage Boom

Top Seat Brace

One Hole Saddle Blocks

3

Engine Mount Bracket

.Reor Seat

.. Fuselage Brace

Leadln.g Wing Bracket Bevel Towards Back

Hose Clamp"'-;"",_~::-

Keep Brack.e!s From Moving

Engine Motlnt Plcde---

Sheet Metal Screw ----oot

Front Fuselage Brace Brackets

2 ENGINE MOUNT $ ASSEMBLY

Silp Through Larg Holes In Seat Brackets

(FRONTI

Slip Seat Tubes Info Fabric Betoro Assembly

Lower Seot TUbe~

Rubber Hand Grip

Push Down Over Upper Control Stick After Inserting Boll

4 SEAT ASSEMBLY

Upper Control stick Spacer

Lower Seat Tube

Ball Joinl Fltflng.

I" Brockel

Elevator Push Rod

Steering push Rod

Threaded Into Ball Joint Fitting. On Steering Bar

Ball Joint Fitting

PedQI Shaft

Use Ltght Coat Of Grease On Pedal. Shaft AI Pedals

ControlS lick Plale ----

Lower Seal Tube

3 CONTROL STIC'K ASSEMBLY

5 PEDDL'E ASSEMBLY

Prepared a Drawn by Bill Boland

PAGE 3

Wing Trailing Edge

Notched Side Of Compression Strut Toward Wing Tip

Notched Side Of Thrust Drag Spar Toward LeadIng Edge

Thrust Drag Spar

Top VIew

Wing Struts Longest One To Rear . Of Plane

34' Wing. Strut Tang Sleel Washer

Leading Edge Root Fitting

6 WING

ASSEMBLY

Three Hole Bracket

Elevator Control Horn

Cenler Spar

Assemble Tubf!$ lnside FQbrlc

Three Hole Bracket

Elevotor Tube

Super Glue

Rudder Tube-_"""

DETAIL "0"

Compression Tube

Elevator Torque Tube

Stabilizer Trailing Edge

t-

Elevator Tube

See DelaU"O"

Center Spar

Rudder Hinge Bracket

DETAIL "E"

Elevator Control Horn

Elevator Tube

Three Hole Brockel

Stabilizer Trailing Edge Tube

Ring CIIP--e; StabilIzer Leading. Edge Tube

a

Rudder Control Gable Same For Other Side -_.

Plostic Washers

Rudder Control Horn

EI.evotor Tube

Three Hole Brackef

Sloblllz.er Leading Edge Tube

Rudder Skid

DETAIL "e"

7 STABILIZER 8 ELEVATOR ASSEMBLY

Assemble Tubes Inside Fabric - View Shown Upside Down

8 RUDDER ASSEMBLY

Assemble Tubes Inside Fabric

-

DETAIL uF" _~~

"'" ,

1\1 .~

J."

;,.

Elevator Pivot Pin

:,.

t Prepared B Drawn by

...,. Bill Boland

PAGE 4

stabilizer

Sub Fin

..------ ----_

»: ------

" 10 STABILIZER STRUT AND

ELEVATOR PUSH ROD ATTACHMENT

Stabilizer

'--. ~Ievator ...._

Sub Fin /'

Stabilizer Strut----' Same For Other Side

9 STABILIZER AND RUDDER ATTACHMENT

Elevator ~

Push Rod

Attach Olhe nd

To Contrdf Stick

"

Control Sflck---

Rudder Control Horn

Cross Cables When Attaching To Rudcter Control Horn

II RUDDER CABLE ATTACHMENT

-

/

----

12 WING ATTACHMENT

13 WING STRUTS AND WING TIPS !NSTALLATION

14 RIB INSTALLATION

Drape Wings Over Fuselage And Attach Leading Edge, Trolling ectge And Thrust Drag Spar With AN4~23A Bolts And Nuts On Both Sides {6 Places Totall.

• Often It Is Necessary To Carefully Smooth And Center The Fabric To Avoid Pulling Too Tight.

. Be Sure To Swing The Compression Strut Straight Befor Pulling Trailing Edge Back To Avoid Tearing The Fabric. Attach The Compression Strut At The Trolling Edge With AN4-23A Bolt And Nut.

Attoch The Wing struts At the Main wheel Tangs With AN5-16A Bolt And Nut, (LQn'9 strut Goes To Trailing Edge Of Wing). Uft The Wing At The Cenler Of The Compression Strut To Avoid Twisting The Wing. Lift Each Strut With Your Foot And Place The Wing Tong In The End Of The TUbe. Attach With AN4-14A Bolt And Nut Front And Rear.

Slide The Wing Tips In And Guide The Front Inlo The Ploslic Socket AI The Leading Edge. Attach At The Trailing Edge With AN4-25A Bolt And Nut.

Use Diagram Below For Rib Installation Sequ.ence. Each Rib Sheuld Be Inserted In The Proper Slot According To Its Length. Slide The Rib, Into The Slot Under Trailing Edge.

~ARN~NG

re 16 14 12 10 e 6 4 2

3 5 7 9 II 13 15 17

WING RIB LAYOUT

DO NOT ATTEMPT TO DO AEROBATICS IN THIS ULTRALIGHT!

This Slde Up

ANY MANEUVERS WHICH EXCEED 30· NOSE UP OR DOWN, OR 60° BANK ANGLE ARE STRICTLY!!! PROHIBITED HI

Hook On To Trailing Edge

Ribs Are Different Lengths

Prepared 8 Drawn by Bill Boland