Hangar 9 Easy Fly 40 User manual

Wing Span .64-3/4 inches

Wing Area .712-1/4 inch2

Approx. Weight .4-3/4-5 1/2 lbs.

Engine Requirements .40-.46 2-cycle

.40-.50 4-cycle

• True UltraCote™ covering

• Positive self-righting flight characteristics

• 90% pre-built

• Extensive hardware kit included

• Break away motor mount prevents engine

damage during minor nose-overs

Specifications

Raising the Standard of Quality

in Almost-Ready-To-Fly Aircraft

ALMOST READY-TO-FLY

PRE-BUILT

90

%

9

HANGAR

TM

INSTRUCTION MANUAL

2

TICKET TO FLY

R/C Pilot Program

The Total Training Package

Congratulations on your selection of the Hangar 9 Easy Fly

40! Your kit comes complete with the “T

ICKET

TO F

LY R/C

Pilot Program,” a detailed video instruction guide designed

to help beginners become successful pilots.

This video guides you through every step of the learning

process — from building tricks and tips through your first solo flights. The

video shows in-depth procedures on radio setup, trimming the plane, and

breaking-in and tuning your engine. It covers the basic flight concepts you

need to know, like takeoffs, landings and, most importantly, how to find and

work with a qualified instructor. You’ll find out just what to expect when

you arrive at the flying field… before you even get there.

When you use the video in conjunction with the complete, photo-illustrated

instruction manual, you’ll gain the confidence and ability to successfully

meet the challenge of R/C flight. This video is an invaluable teaching aid

which will shorten the time it takes to properly learn to operate and fly the

Easy Fly 40.

Good Luck and Good Flying!

TM

3

Table Of Contents

Introduction 3

Contents Of Kit 4

Equipment Required 5

Tools And Supplies Required 5

Field Equipment Required 6

Optional Field Equipment 7

Section 1: Assembling The Wings 8

Section 2: Joining The Wing Halves 9

Section 3: Hinging The Rudder And Elevator 12

Section 4: Installing The Aileron Servo Trays 13

Section 5: Assembling The Fuselage 16

Section 6: Installing The Nose Gear 17

Section 7: Installing The Wing Dowels 18

Section 8: Assembling The Fuel Tank 19

Section 9: Installing The Fuel Tank 21

Section 10: Installing The Control Horns 22

Section 11: Installing The Horizontal & Vertical Stabilizers 24

Section 12: Installing The Engine 26

Section 13: Installing The Radio 29

Section 14: Installing The Linkages 32

Section 15: Setting Up The Radio 38

Section 16: Balancing The Model 39

Pre-Flight Check 40

Pre-Flight At The Field 41

Flight Instructions 42

AMA Safety Codes 43

Glossary 44

Introduction

Congratulations!

You are the proud owner of the highest quality almost-ready-to-fly (ARF) sport trainer available. The Easy Fly

40 is professionally built and pre-covered by craftsmen using genuine UltraCote

®

covering. The positive self-

righting flight characteristics and excellent slow-speed handling make the Easy Fly 40 one of the easiest-to-fly

airplanes available. Beyond its positive, gentle flight mannerisms, the Easy Fly 40 also offers outstanding

sport aerobatic capabilities. Loops, rolls, sustained inverted flight, and even outside maneuvers are all well

within its flight envelope.

In order for you to get the best performance and most enjoyment from your Easy Fly 40, it is important to

carefully read and follow this manual. If you’re a first-time flier, we strongly suggest that you seek qualified

help during your first flights. Your local hobby shop will be able to put you in touch with qualified pilots and a

local club.

Note: Due to temperature changes during shipping, the covering on your Easy Fly may be slightly wrinkled.

The careful use of a heat gun or iron is recommended to shrink the UltraCote

®

until its taut.

Warning

An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in

open areas, preferably AMA (Academy of Model Aeronautics) approved flying sites, and have an experienced

modeler/pilot preflight your aircraft before its first flight and perform the aircraft’s first test flights. Please

follow all instructions included with your radio and engine. We cannot stress strongly enough the importance

of having an experienced pilot preflight your aircraft and be present during your first test flights!

4

The Easy Fly 40 is professionally built and

pre-covered by craftsmen using genuine UltraCote®

covering. UltraCote is completely reparable and can

be found at your local hobby shop.

ULTRACOTE

UltraCote is a registered trademark of Carl

Goldberg Models

®

Contents Of Kit

5

A. Fuselage (#HAN1401)

B. Right wing half with aileron (#HAN1402)

C. Left wing half with aileron (#HAN1402)

D. Vertical stabilizer with rudder (#HAN1403)

E.

Horizontal stabilizer with elevator

(#HAN1404)

1. Pushrods

2. Aileron servo mounts (2)

3. Main landing gear

4. Nose landing gear

5. Spinner

6. Motor mounts and hardware

7. Wheels (3)

8. Fuel tank and hardware

9. Rubber bands (8)

10. Control horns

11. Wing joiner

A

B

C

E

D

1

11

9

8

7

6

5

4

3

2

10

R/C Radio System

4 Channels (minimum)

4 Standard Servos

Standard 450-650 mAh Battery

Recommended JR Systems

JR F400 FM

JR XP642

JR XP783

JR XP8103

R/C Engine

.40-.45 2-Cycle with Muffler

Recommended Thunder Tiger Engine

GP .42 with Muffler

R/C Aircraft Propeller

10-6 Prop with a .40-.46 Size Engine

6

Equipment Required

Adhesives

CA (cyanoacrylate) Glue (instant/thin and medium viscosity)

CA Remover (dissolve)

5-Minute Epoxy

30-Minute Epoxy

Tools

Clips (e.g. clothespins, binder clips)

Cloth

Drill and Assorted Drill Bits

Heat Gun

Heat Iron

Hobby Knife

Masking Tape

Needle Nose Pliers

Paper Towels

Pencil

#1 and #2 Phillips Screwdrivers

Rubbing Alcohol

Ruler (straight edge)

Sandpaper

Scissors

Straight Screwdriver

Thread Lock (e.g., Loc Tite Blue)

Toothpicks

90-Degree Triangle

Wax Paper

Z-Bender Pliers

Tools And Supplies Required

Field Equipment Required

HAN3000 – 2-cycle Performance Plug MDC101 Glow Driver Model Airplane Fuel

HAN 3005 – Extra Life Sport Plug

HAN104 12V Super Starter HAN102 12V Battery HAN118 Fuel Pump

HAN2510 Glow Plug Wrench

7

Optional Field Equipment

Extra Propellers Flight Box Power Panel

Prop Wrench Miscellaneous Tools Paper Towels

#64 Rubber Bands After Run Oil Extra Glow Plugs

8

❑ 1. Carefully remove the aileron from the right wing panel.

Note where the hinges and the aileron torque rod fit into

the aileron.

❑ 2. Mix a small amount of 30-minute epoxy, carefully

following the instructions included with the epoxy.

❑ 3. Using a toothpick, apply epoxy into the ailerons’ torque

rod hole. Fill the hole 1/2 full.

❑ 4. Replace the aileron on the right wing half. Make sure

the hinges slide in place and the aileron torque rod

inserts into its respective hole in the aileron. The gap

between aileron and wing should be a constant 1/16”.

❑ 5. Wipe off any excess epoxy using a paper towel and

rubbing alcohol.

❑ 6. Deflect the aileron and apply a small amount of thin CA

glue to each hinge. Make sure that the CA glue

penetrates into the aileron and wing while maintaining a

1/16” aileron gap.

❑ 7. Wipe off any excess CA glue using CA remover and a

paper towel.

❑ 8. Repeat this process for the left wing (Steps 1-7).

Note:

After the CA has dried completely, check to ensure that

the hinges are secure by pulling firmly on the ailerons.

Important:

The ailerons are fitted in place but not glued in. They

must be correctly glued prior to flying.

9

Left Wing Panel with Aileron and Hinges

Right Wing Panel with Aileron and Hinges

CA Remover

30-Minute Epoxy

Thin Instant CA Glue

Paper Towels

Rubbing Alcohol

Toothpicks

Section 1: Assembling The Wings

Parts Needed Tools Needed

❑ 1. Using a pencil, mark both wing roots (the exposed

wood end of the wing halves) as shown.

❑ 2. Using a hobby knife, carefully cut out the marked

section.

Important:

Do not cut into hard wood wing joiner section.

10

Aileron Servo Mounts (2)

Dihedral Brace

Left Wing Half from Section 1

Right Wing Half from Section 1

Standard Servo (1)

30-Minute Epoxy

Hobby Knife

Masking Tape

Paper Towels

Pencil

Rubbing Alcohol

Ruler

Wax Paper

Section 2: Joining The Wing Halves

Parts Needed Tools Needed

❑ 3. Locate the dihedral brace (also called the wing joiner).

Using a ruler and pencil, mark the exact center of the

brace as shown.

❑ 4. Mix approximately 2 ounces of 30-minute epoxy. In

this step, be sure to use plenty of epoxy. Using a scrap

piece of wood, smear the epoxy into the wing joiner

cavity of both wings. (Remember, use plenty of epoxy.)

❑ 5. Coat one half of the dihedral brace with epoxy up to the

line. Note the orientation of the V of the dihedral

brace. Install the epoxy-coated side of the dihedral

brace into a wing half up to the line, making sure the V

of the dihedral brace is positioned correctly as shown.

11

Section 2: Joining The Wing Halves

CONTINUED

❑ 6. Apply epoxy to the exposed area (other end) of the

dihedral brace. Uniformly coat both wing roots with

30-minute epoxy.

❑ 7. Carefully slide the two wing halves together. Firmly

press the two halves together, allowing the excess

epoxy to run out. Using rubbing alcohol and a paper

towel, clean off the excess epoxy.

Important:

Be sure the wings are pressed firmly together at the

center section. Be sure that the leading and trailing

edges line up properly. Use masking tape as necessary

to hold the wing halves in position.

❑ 8. Place a 12” x 12” sheet of wax paper on the edge of a

flat table. Place the center section of the wing on the

wax paper with the aileron torque rod hanging off the

edge of the table. Prop up each wing tip 2-1/2 inches

off the table as shown. Books work well for this.

❑ 9. Wipe off any excess epoxy using rubbing alcohol and

paper towels. Allow the wing to set undisturbed

overnight to dry completely.

12

Section 2: Joining The Wing Halves

CONTINUED

13

Horizontal Stabilizer with Elevator and Hinges

Vertical Stabilizer with Rudder and Hinges

CA Remover

Paper Towels

Thin Instant CA Glue

Section 3: Hinging The Rudder And Elevator

Parts Needed Tools Needed

❑

1. Push the elevator and horizontal stabilizer together until

there is a constant 1/16” gap between the two and the

edges are lined up correctly.

❑ 2. Deflect the elevator and apply thin CA glue at the

hinges so that it absorbs both into the stabilizer and the

elevator (4 places).

❑ 3. Using the same technique, hinge the rudder to the

vertical stabilizer.

❑ 4. Wipe off any excess CA using CA remover and a paper

towel. Set these assemblies aside for now.

Note: After CA has dried completely, check to ensure that the

hinges are secured by pulling firmly on the control

surfaces.

14

❑ 1. Mix a small amount of 5-minute epoxy as per the

instructions included with the epoxy. Remember, once

this epoxy is mixed, you have only 5 minutes of

working time until it dries.

❑ 2. Spread a thin layer of epoxy over the entire surface of

one side of an aileron tray.

❑ 3. Join the two aileron trays as shown and clamp them

together using four clips. Be sure the two trays are

properly aligned. Wipe off any excess epoxy with a

paper towel and set aside to dry for 15 minutes.

❑ 4. Using a ruler, measure the distance on the bottom of

the wing at the center line 5-1/2 inches from the trailing

edge and mark with a pencil.

❑ 5. Next, measure 3-3/4 inches from the leading edge back

to the center line and mark with a pencil.

Aileron Servo Trays (2)

Wing Center Section Tape

Clips (e.g., clothespins,

binder clips) (4)

5-Minute Epoxy

Hobby Knife

Masking Tape

Paper Towels

Pencil

Ruler

Section 4: Installing The Aileron Servo Trays

Parts Needed Tools Needed

15

❑ 6. Unclamp the aileron tray when dry and position it on

the center line so the two marks are visible on the

inside of the aileron tray.

❑ 7. Carefully trace around the outside of the aileron tray

using a pencil.

❑ 8. Remove the aileron tray. Using a sharp hobby knife,

carefully cut through the plastic covering. Be careful

not to cut into the wood on the line you just made in

Step 7.

❑ 9. Carefully remove the covering in the aileron tray area.

This is necessary so that the tray will properly adhere to

the wing.

❑ 10. Mix a small amount of 5-minute epoxy and spread it

over the entire area of one side of the servo tray.

S

ection

4: Installing The Aileron Servo Trays

CONTINUED

16

❑ 11. Place the aileron tray, glue side down, on the exposed

wood area on the bottom of the wing and gently press it

into position. Use masking tape if necessary to hold in

position until dry. Allow 15 minutes for the epoxy to

cure.

❑ 12. Using a sharp hobby knife, carefully cut out the balsa

wood from the inside section of the aileron tray and

remove.

❑ 13. Locate the wing center tape (white adhesive-backed

tape) and remove the adhesive backing. Starting at the

edge of the aileron tray, apply the tape around the wing

at the center section, ending at the other side of the

tray. Use a hobby knife to trim the excess length of

tape. Your wing is now complete.

❑ 14. Locate the small blue decal (square in shape) on the

decal sheet included with your kit. Apply this decal to

the leading edge of the wing to cover the wing center

tape that you have just applied. Press firmly to ensure

that the decal adheres properly to the wing.

S

ection

4: Installing The Aileron Servo Trays

CONTINUED

17

❑ 1. Locate the main landing gear slot in the bottom of the

fuselage. Position the two landing gear straps across

the slot as shown and drill four 1/16” holes using the

straps as a guide. Remove the straps after all four holes

are drilled.

❑ 2. Locate the two main landing gear struts and insert them

into the landing gear slot as shown. Make sure the ends

fit into the holes in the edges of the slot.

❑ 3. Reposition the landing gear straps over the 1/16” hole

you drilled in Step 1. Screw into position with the four

sheet metal screws provided.

❑ 4. Place the wheels on the ends of the struts and secure

them with the supplied wheel collars. Use thread lock

on the collar screws.

Fuselage

Main Landing Gear (2 pcs)

Main Landing Gear Hardware

Wheels (2 pcs)

Wheel Collars with Screws (2 pcs)

Drill with 1/16” Drill Bit

#1 and #2 Phillips Screwdrivers

Thread Lock

Section 5: Assembling The Fuselage

Parts Needed Tools Needed

18

❑ 1. The nose gear mount is pre-assembled onto the front

firewall of the fuselage. Locate the nose gear. On the

straight end, first slide the steering arm onto the nose

gear (note the orientation as shown in the photo). Use

thread lock and a #2 Phillips screwdriver to secure the

steering arm in place. Next, install a collar and secure it

in place with the thread lock and a machine screw. Now

slide the spring into position.

❑ 2. Insert the nose gear assembly from Step 1 into the nose

gear mount (attached to the front of the fuselage). Be

sure the spring stays in position and rests against the

nose gear mount. Install the collar on the top end of the

landing gear flush with the landing gear, and secure it

into position with a screw and the thread lock.

❑ 3. Attach the nose wheel and hold it in place using a

wheel collar and screw.

Nose Gear Wheel (1)

Spring Wheel Collar with Screws (2)

Steering Arm

#2 Phillips Screwdriver

Thread Lock

Section 6: Installing The Nose Gear

Parts Needed Tools Needed

19

❑ 1. Using a sharp hobby knife, carefully cut the covering

around the four holes as shown, leaving a circle that the

dowel will be pressed into.

❑ 2. Install the two dowels and position them so that an

equal amount of dowel extends from each side of the

fuselage. Using thin CA glue, apply five drops around

each side of the wing dowel (4 places) where the dowel

touches the fuselage.

❑ 3. If necessary, use a paper towel and CA remover to wipe

off any excess CA glue.

Fuselage

Wing Dowels (2)

CA Remover

Hobby Knife

Paper Towel

Thin Instant CA Glue

Section 7: Installing The Wing Dowels

Parts Needed Tools Needed

20

Clunk (brass fuel pickup)

Copper Tube, Long (vent)

Copper Tube, Short (pickup)

Fuel Line, Small

Fuel Tank

Plastic Cups (2)

Rubber Stopper

3mm Screw and 3mm Nut

Hobby Knife

#1 Phillips Screwdriver

Section 8: Assembling The Fuel Tank

Parts Needed Tools Needed

❑

1. Locate the black rubber stopper. Insert the short copper

tube into one of the open holes in the stopper so that an

equal amount of tube extends from each side. This tube

will be the fuel tank pickup tube.

❑ 2. Locate the long copper tube and bend it using your

fingers, as shown. This tube will be the fuel tank vent

tube.

❑ 3. Slide this tube into the other open hole of the stopper,

as shown.

❑ 4. Slide the two white plastic caps over the copper tubes

as shown. Note the orientation of the caps. The small

inside cap and the three “pegs” face away from the

black rubber stopper. The large outside cap and the

“raised center” go away from the black rubber stopper.

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Hangar 9 Easy Fly 40 User manual

Hangar 9 Easy Fly 40 User manual

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