AeroWorks Sport Cub S2 ARF-QB Assembly Manual

[Page 1] AeroWorks Sport Cub S2 ARF-QB

1 50cc Sport Cub S2 ARF-QB (Quick Build) ASSEMBLY MANUAL AEROWORKS 4903 Nome Street, Denver, CO. 80239 - Phone 303-371-4222 - Fax 303-371-4320 E-mail - [email protected] ...

[Page 2] AeroWorks Sport Cub S2 ARF-QB

2 TABLE OF CONTENTS 1 Page Aeroworks Contact Information ………………………………………………………………. 3 Introduction ……………………………………………………………�...

[Page 3] AeroWorks Sport Cub S2 ARF-QB

3 4903 Nome Street Denver, CO 80239 Phone: (303) 371-4222 Fax: (303) 371-4320 Website: www.aero-works.net E-mail: [email protected] Tech Support: [email protected] Thank you for choosing the Aeroworks Sport Cub ...

[Page 4] AeroWorks Sport Cub S2 ARF-QB

4 INTRODUCTION Your new Sport Cub S2 ARF-QB is a scale airplane. The aircraft builds easily, quickly, and precisely due to its state of the art CAD design, LASER cut technology, and high quality in- cluded hardware. We hope you enjoy build...

[Page 5] AeroWorks Sport Cub S2 ARF-QB

5 KIT CONTENTS 50cc Sport Cub S2 ARF-QB Materials List Basic Aircraft Parts Fuselage with pre-installed vertical fin - Covered with Oracover, pre-drilled three holes for tail wheel assembly: (12) 4-...

[Page 6] AeroWorks Sport Cub S2 ARF-QB

6 (2) 8-32 blind nuts pre-installed for wing mounting (2) 6-32 blind nuts pre-installed for wing struts mounting (5) Large Pin Point Hinges glued for Flap (6) Large Pin...

[Page 7] AeroWorks Sport Cub S2 ARF-QB

7 # 6 (2) 4-40x300mm threaded pushrods (2) 4-40 Solder threaded coupler with nuts (4) 4-40 Ball Links (4) 4-40x16mm hex head bolts ...

[Page 8] AeroWorks Sport Cub S2 ARF-QB

8 Hardware: ITEMS NEEDED TO COMPLETE • 50cc Gas engine and ignition • J-Tec 50cc Wrap Around Slim Fit Muffler • 2 x aileron servos (min 172 in./oz. Torque @ 6 volt, Digital, Metal Geared) • 2 x flap servos (min 172 in./oz. Torq...

[Page 9] AeroWorks Sport Cub S2 ARF-QB

9 1. Open your kit slowly and take care not to dam- age any parts of the kit. Remove all parts from their plastic protective covers for inspection. Before doing any assembly it is recommended that the canopy, and instrument panel be re- move...

[Page 10] AeroWorks Sport Cub S2 ARF-QB

10 1. Before doing any assembly or installation of any decals it is very important to re-shrink or re- tighten the already applied covering. Due to the shipping process, heat and humidity changes from different climates, the covering may be- ...

[Page 11] AeroWorks Sport Cub S2 ARF-QB

11 1. Go over all seams and color overlaps with your sealing iron. Note: Even if your models covering has no wrin- kles out of the box it is still very important to go over all seams and overlaps to make certain they are sealed securely....

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12 1. Your model is covered with Ultracote™ covering. In case of repairs, the colors are: Red/White Scheme True Red #866 Black #874 White #870 Ultracote™ Colors 2. Yellow/Black Scheme Cu...

[Page 13] AeroWorks Sport Cub S2 ARF-QB

13 Aileron/Flap Servo Installation 1. The ailerons/flaps have been pre-hinged and glued to the wing panels and are ready for flight. No other steps are necessary for hinging. Gather the following items: ◊ 1 - Wing panel ◊ 1 - ...

[Page 14] AeroWorks Sport Cub S2 ARF-QB

14 5. Pull aileron extension through root end of wing. 6. Pull flap extension through root end of wing. Note: Taping servo lead to the inside of the wing panel will help to prevent lead from dropping back inside of wing panel du...

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15 9. Finished panel shown with servos installed. Aileron/Flap Control Linkage Installation 1. Gather the aileron and flap control linkage parts as shown below. ◊ 1 - 3” pushrod - Aileron ◊ 1 - 3” Pushrod - Flap ◊ 4...

[Page 16] AeroWorks Sport Cub S2 ARF-QB

16 5. Use thick CA on each screw prior to installing to lock screws in place. Note: CA glues have a fast drying time. Remember to work quickly. 6. Align the left and right sides of the control horns to the mounting holes and mou...

[Page 17] AeroWorks Sport Cub S2 ARF-QB

17 Strut assembly and Installation 1. Gather the following items for the strut installa- tion as shown below. ◊ 2 - strut mounts ◊ 2 - 6-32 mounting bolts ◊ 2 - strut eyelets 2. Use the 6-32 mounting bolt to install the st...

[Page 18] AeroWorks Sport Cub S2 ARF-QB

18 5. Apply a small drop of medium CA to the strut eyelet as shown. Screw the eyelet into the pre- drilled hole in the bottom of the wing. Note: CA glues have a fast drying time. Remember to work quickly. 7. Finished strut mount...

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19 9. The foam transportation pad can slip over the two eyelets and kept in place using the set pins and cotter pins. This will prevent the struts from damaging the wing during transport. 11. Be careful not to over tighten the bolts as th...

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20 13. Cotter pin installation shown below. 15. Finished strut assembly shown. Remove the bot- tom set pins to fully collapse the strut as shown below. 14. The remaining 6-32 bolts will be used to mount the struts to the fuse. It is recom...

[Page 21] AeroWorks Sport Cub S2 ARF-QB

21 Rudder Installation 1. Gather the rudder, four hinges, rubbing alcohol, petroleum jelly and epoxy materials as shown. Use 15-30 minute epoxy to ensure adequate working and cleanup time. RUDDER AND PULL – PULL CABLE ASSEMBLY 2. Mix...

[Page 22] AeroWorks Sport Cub S2 ARF-QB

22 5. Carefully slide the rudder onto each hinge and against the trailing edge of the fin. Wipe away excess epoxy with alcohol wetted wipes. 6. Ensure there is no gap between fin and rudder. Allow epoxy to fully cure. Check you have...

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23 2. Gather the rudder control horn parts as shown below. Two ball link assemblies, two left and two right side control horns. Assemble the ball links between the control horns as shown. Se- cure with nylon lock nut. Start with the cente...

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24 6. Mount rudder control horns using six wood screws. 7. Repeat the above steps for mounting the other side rudder control horn. 8. Feed one rudder cable through the pre installed cable exit tube in the rear of the fuse toward the...

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25 11. Using an X-ACTO knife clean away any burrs from brass swags. This will allow the rudder cable to pass through brass swage easily. 12. Thread cable through brass swage tube. 13. Thread cable through the threaded coupler hole, and b...

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26 16. Crimp the brass swage tube with a crimping tool or pliers. 17. Cut off excess cable as shown 18. A drop of thin CA may be applied to the swage tube to help secure the cable. 19. Attach ball links to the rudder servo arm and th...

[Page 27] AeroWorks Sport Cub S2 ARF-QB

27 20. Attach servo arm to servo as shown below. 21. Plug the rudder servo into the rudder channel of the receiver and power up. Turn on transmitter to center rudder servo. Ensure servo trim and sub trims are centered. Note: On met...

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28 24. Follow the same steps for the opposite side of the rudder as shown below. Rudder pull pull as- sembly is now complete. ...

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29 Elevator Servo Installation 1. The elevators have been pre-hinged and glued to the stabs and are ready for flight. No other steps are necessary for hinging. Gather the following items for the stab/elevator assembly, ◊ 2...

[Page 30] AeroWorks Sport Cub S2 ARF-QB

30 5. Mounting the elevator servos in opposing direc- tions will allow the servo spline to align per- fectly which will result in equal throw and elimi- nate the need for a Y reverser or complex radio mix. 6. Layout the servo on the fuse t...

[Page 31] AeroWorks Sport Cub S2 ARF-QB

31 2. Assemble the pushrod and control horn assem- bly as shown. The ball link goes between the left and right sides of the control horn sides and is secured with a nylon lock nut. Start with the center hole in the control horn. The ball l...

[Page 32] AeroWorks Sport Cub S2 ARF-QB

32 6. Mount the control horn using six wood screws. 1. Gather the following items shown below: ◊ 1 - Carbon support rod ◊ 4 - L brackets ◊ 2 - 6-32 x 10mm bolts ◊ 4 - 6-32 x 15mm bolts ◊ 2 - 6-32 x 20mm bolts ◊ ...

[Page 33] AeroWorks Sport Cub S2 ARF-QB

33 4. Slide the carbon support rod into the stab and then slide the support rod through the slot in the fuse as shown. 5. Apply blue loctite to the 6-32 mounting bolts as shown. Use 10mm bolt for the rear bracket and 15mm bolt for...

[Page 34] AeroWorks Sport Cub S2 ARF-QB

34 8. Repeat the previous steps for the remaining stab assembly. Stab Adjustment 1. Set the stab incidence to zero for general flying. This can be achieved by setting the front L bracket on the top of the pre-installed plywood space...

[Page 35] AeroWorks Sport Cub S2 ARF-QB

35 4. Once the desired position has been located, se- curely tighten the mounting bolts. 2. Test fit the top flying wires as shown, the upper flying wires will be longer than the bottom. 3. Use the 4-40 bolt and nut to mount the flying ...

[Page 36] AeroWorks Sport Cub S2 ARF-QB

36 4. Loosen the lock nut and adjust the flying wire to the correct length as shown. 5. Once wires are the correct length pass the 4-40 mounting bolt through the top of the stab as shown. 6. Pass the 4-40 mounting bolt through the bot...

[Page 37] AeroWorks Sport Cub S2 ARF-QB

37 9. Adjust the flying wire lengths to ensure that the flying wires are not twisting the stabs. The fly- ing wires should be adjusted so they are only able to move about 1/2” back and forth or until the stabs have no play in any directio...

[Page 38] AeroWorks Sport Cub S2 ARF-QB

38 MAIN LANDING GEAR ASSEMBLY 2. Use 6-32 bolts, flat washers, and blue loctite to mount the rear landing gear/strut mount. 3. Mount the other rear landing gear/strut mount as shown below. 4. Use 6-32 bolts, flat washers, and blue l...

[Page 39] AeroWorks Sport Cub S2 ARF-QB

39 6. Use 6-32 mounting bolts and 6-32 lock nuts to secure the landing gear strut in place as shown. 7. Install the remaining landing gear strut following the previous mounting instructions. 8. Slide the 6-32 mounting bolt through the f...

[Page 40] AeroWorks Sport Cub S2 ARF-QB

40 10. Repeat the steps for the remaining side. Final installation of shock mount shown below. 11. Attach shock to shock mount using a 6-32 bolt and lock nut as shown. 12. Secure the shock to the landing gear strut with a 6-32 bolt and l...

[Page 41] AeroWorks Sport Cub S2 ARF-QB

41 14. Repeat the steps for the remaining side. Final installation of shocks shown below. 15. Gather the two stock wheels, two wheel spacers, four wheel collars, two hub caps, and six hub cap mounting screws as shown. 16. Slide one of th...

[Page 42] AeroWorks Sport Cub S2 ARF-QB

42 18. Slide the wheel followed by the remaining wheel collar onto the axle. Tighten the wheel collar set screw. 19. Using the 3 mounting screws, mount the hub cap as shown below. 20. Repeat the wheel mounting steps for the follow- ing s...

[Page 43] AeroWorks Sport Cub S2 ARF-QB

43 2. Slide the spacer followed by the wheel onto the axle. Do not use the inner wheel collar that is used in the stock wheel installation. 3. Slide the remaining wheel collar onto the axle. Tighten the wheel collar set screw. Optional...

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44 Tail Wheel Installation 2. Align rudder tiller steering arm with pre drilled mounting holes at bottom of rudder. 3. Apply a drop of thick CA to the tiller arm mounting screws before inserting in the pre- drilled holes. Note: CA glu...

[Page 45] AeroWorks Sport Cub S2 ARF-QB

45 6. Mount the tail wheel struts using three wood screws. 7. Tape the rudder boost tab in place to keep the rudder aligned while tightening the steering springs. 5. Place a drop of thick CA on tail wheel strut mounting screws before ...

[Page 46] AeroWorks Sport Cub S2 ARF-QB

46 10. Repeat spring installation for other side. 11. Bottom view of completed tail wheel installa- tion. 9. Twist spring end tight with pliers. ...

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47 Engine Installation 1. The 50cc Sport Cub S2 will accept a wide range of engine types. The DA-50 rear carburetor engine with Pitts style muffler, was mounted and used for the test flights. 2. DA 50 with 2 1/2” Stand offs, sli...

[Page 48] AeroWorks Sport Cub S2 ARF-QB

48 7. Use 5 minute epoxy to glue the mounting tem- plate and stand off block together as shown. Al- low epoxy to fully cure before moving on to the next step. 9. Pass the engine mounting bolts through F1 as shown below. Make sure a large ...

[Page 49] AeroWorks Sport Cub S2 ARF-QB

49 11. Slide the mounting block on the bolts as shown below. Make sure the mount is positioned to give the correct right thrust. 12. Slide a fender washer, 1/4” standoff, and another fender washers onto the bolts as shown. Note:...

[Page 50] AeroWorks Sport Cub S2 ARF-QB

50 14. Distance from front of firewall to front of engine prop hub is 7 7/8”. Note: Use aluminum spacers (supplied) and washers (not supplied) to achieve correct distance. Throttle Servo and Choke Installation 1. Gather t...

[Page 51] AeroWorks Sport Cub S2 ARF-QB

51 4. Attach throttle pushrod to the carburetor throttle arm with the 4/40 ball link. 5. Gather the supplied throttle servo mount as shown. It may be necessary to remove the bot- tom corner of the mount. 6. Test fit throttle servo mount...

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52 9. Place servo mounting box in fuse use tape or clamps to ensure the servo mount does not move until the epoxy sets. 8. Apply 5 minute epoxy to the servo mounting box as shown. 10. Assemble brass threaded coupler to 4-40 ball link a...

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53 13. Gather the soldering tools as shown below. Note: For best results we recommend a high quality Silver Solder like “Sta-Brite” silver solder. 12. Remove pushrod from throttle arm on carburetor and cut throttle pus...

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54 17. If installing a choke servo use the provided mounting tray and hardware shown below. Fol- lowing same installation steps used for installing throttle servo install choke servo. 16. Attach the throttle pushrod with the 4/40 ball links...

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55 20. Location of manual choke pushrod shown be- low. ...

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56 2. Position the ignition module on the side of the engine mounting box and mark the location of the nylon tie holes as shown. 3. Use a 1/4” bit to drill the ignition module mounting holes. 4. Thread nylon tie through mounting h...

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57 6. Secure ignition module with nylon ties as necessary. 7. Mount ignition battery behind firewall with ny- lon tie and foam padding. 8. Mount ignition regulator as desired. Secure all connectors with tape, safety clip or similar. 9. ...

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58 11. Finished switch and regulator installation shown below. ...

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59 Fuel Tank Assembly 1. Gather the fuel tank parts as shown below. ◊ 1 - Fuel tank ◊ 1 - Hardware ◊ 1 - Brass barbs ◊ Fuel Tubing (not supplied) FUEL TANK ASSEMBLY AND INSTALLATION 2. Locate the (2) supplied brass fu...

[Page 60] AeroWorks Sport Cub S2 ARF-QB

60 5. Final assembly of rubber fuel stopper with fuel pick up tube shown below. 6. Install air vent tube into rubber stopper and bend upward. Note: No brass barbs are required for the air vent tube. 7. Install the fuel tubing and...

[Page 61] AeroWorks Sport Cub S2 ARF-QB

61 9. Secure the rubber stopper with set screw. Take care not to strip threads by over tightening set screw. Fuel Tank Installation 1. Gather the fuel tank parts as shown below. Fuel tank, fuel tubing, foam rubber, fuel “T”, fuel...

[Page 62] AeroWorks Sport Cub S2 ARF-QB

62 4. Use small nylon ties to secure fuel line. Note: Gasoline will cause the fuel line to expand over time. Always secure fuel lines with nylon ties to prevent them from pulling off during flight. 5. Thread nylon ties under tan...

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63 9. Secure fuel pick up line to engine carburetor with small nylon tie. 10. Gather the fuel filler dot and drill bits as shown below. Note: We recommend you start with a smaller size drill bit then increase the bit size to the ...

[Page 64] AeroWorks Sport Cub S2 ARF-QB

64 13. Use thick CA to secure fuel dot in fuse. 14. Feed filler line through dot and plug line into filler plug as shown. 15. Feed vent line tubing through bottom of fuse. Cut off excess fuel line. Note: Place a zip tie around the ve...

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65 1. Gather the custom 50cc slim fit muffler avail- able through Aeroworks. This muffler will fit fully enclosed in the cowl. Pitts Muffler Installation 2. Install pitts muffler using mounting bolts sup- plied with muffler. Note: Use ...

[Page 66] AeroWorks Sport Cub S2 ARF-QB

66 1. Using a covering iron seal the covering around the air exit holes at fuse bottom as shown be- low. 2. Use a hobby knife to remove the covering around the hot air exit holes. 3. Remove the (4) Phillips head screws holdi...

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67 5. Use 30 Minute epoxy to secure the canister mount as shown. 6. Install the canister mount in the fuse. Allow ep- oxy to fully cure before moving on to the next step. 7. Canister mount viewed from front as shown be- low. 4. Rem...

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68 9. Slide the canister into the canister tunnel as shown below. 10. Reinstall motor to mounts. 11. Secure the header in place using the mounting bolts and gasket provided with your engine. Use blue Loctite to secure the bolts. 12....

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69 13. Canister installation is now complete. ...

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70 1. Gather the materials as shown below. Template material, hobby knife, ruler, tape, marker and pencil. COWL INSTALLATION 2. Tape the provided template material to the bot- tom of the fuse as shown below. 3. Align the template to the ...

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71 5. Trace around the head of the engine being care- ful to keep the template in the same location. 6. Use a hobby knife to cut out the engine cylinder exit opening as shown. 7. Check the fit of the template at this time. It may be n...

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72 10. Remove the template and use a rotary cutting tool and sanding drum to cut out the openings in the cowl. Note: Take care not to cut or scratch the cowl. 11. Finished cowl/slim fit muffler installation shown below. S...

[Page 73] AeroWorks Sport Cub S2 ARF-QB

73 5. Use a pen to mark the location of the template on the fuse. Be careful not to dent the wood sheeting with the pen. 6. Remove template from fuse as shown below. 7. Bolt cowling in place and reinstall template as shown below. ...

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74 1. Gather the radio components as shown below. Battery, Switch, Regulator if used, receiver, foam rubber and Velcro one wrap straps. RADIO INSTALLATION 2. Final switch positioning is left to the builder. Aeroworks recommends the swi...

[Page 75] AeroWorks Sport Cub S2 ARF-QB

75 6. Run aileron and flap extensions from the re- ceiver, behind the rear window and out the top of the fuse as shown. This will help maintain the scale appearance of airplane. 7. Typical radio installation shown below. Note: If model...

[Page 76] AeroWorks Sport Cub S2 ARF-QB

76 Decal installation 1. Decals supplied with the kit may vary from the photos below. Decal installation instructions are for reference purposes only. Gather supplied decals, transfer tape, ruler, scis- sors, hobby knife, plastic squee...

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77 7. Use a covering iron to reseal the covering as shown. 8. Remove backing from decal sheet. 5. Position fuselage decal as shown below. Mark location where N numbers cross the black strip on the fuse. 6. Remove portion of fuse str...

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78 11. Using a plastic squeegee or credit card. Spread decal smooth and remove all excess application fluid. Let decal set until dry enough to be able to remove transfer tape with out removing decal. Do not leave until completely dry or trans...

[Page 79] AeroWorks Sport Cub S2 ARF-QB

79 1. Slide the wing tube in the fuse wing tube sleeve. Slide the wings on the wing tube PRE-FLIGHT PREPARATION 2. Remove the foam pad and attach the middle strut supports using the set pins and cotter pins as shown. 3. Secure the aile...

[Page 80] AeroWorks Sport Cub S2 ARF-QB

80 5. Gather four 8-32 wing mounting bolts and four #8 rubber backed washers for preparation of mounting the wings. 6. Slide the rubber backed washers on the wing mounting bolts and insert bolts through the fuse side and into the wing ro...

[Page 81] AeroWorks Sport Cub S2 ARF-QB

81 1. Aeroworks has included the new CG Buddy with the Sport Cub S2. This handy tool will al- low the builder to balance the airplane without the need for an assistant. 2. Gather the CG buddy as shown below: Center Of Gravity– CG Budd...

[Page 82] AeroWorks Sport Cub S2 ARF-QB

82 8. Lift airplane from center handle as shown, plane should sit level when lifted. Balance the Sport Cub S2 without fuel in the tank with the batteries in- stalled and READY TO FLY. Try to balance the model by moving the batteries and rece...

[Page 83] AeroWorks Sport Cub S2 ARF-QB

83 Control Throws 1. The amount of control throw should be adjusted using mechanical means as much as possible and then electronically with the radio. The control throws are shown in degrees and inches of deflec- tion measured at the wid...

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84 Control Throw Deflection Table Low Rate Medium Rate Aileron 7/8” or 20˚ up 1 1/4” or 30˚ up 7/8” or 20˚ down 1 1/4” or 30˚ down Rudder N/A” or 25˚ left N/A” or 35˚ left N/A” or 25˚ right N/A” or 35...

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85 Preflight Checks Center of Gravity: Check CG is set properly. Engine: The engine should run smoothly at all throttle settings with smooth transition from idle to full throttle without stalling or hesita- tion. Do not fly an unr...

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86 50cc Sport Cub S2 ARF-QB NOTES ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________...