WattAge Mini-Max EP Instructions Manual

Brand: WattAge

Model: Mini-Max EP

Category: Toys & accessories

Type: Instructions Manual

INSTRUCTIONS FOR FINAL ASSEMBLY

The Wattage Mini-Max EP is distributed exclusively by Global Hobby Distributors 18480 Bandilier Circle, Fountain Valley, CA 92728

Thank you for choosing the Wattage Mini-Max EP for your next E-power project. The Mini-Max EP is

a small, lightweight, slow-flying electric-powered airplane built specifically to be flown indoors or in small

fields or parks - even in your backyard!

The Mini-Max EP features a prebuilt sheet-foam fuselage, molded foam wing panels and sheet-

foam flying surfaces that add up to make a lightweight, yet durable structure that is very easy to repair

in the event of a mishap. And because it is lightweight, performance using the included 280 size motor

and gear box is excellent. The airplane can fly very slowly, yet has enough power for loops and other

simple aerobatics. Because of its broad flight envelope, the Mini-Max EP is a perfect choice for both the

experienced pilot and for those just learning to fly.

When you open the box, you will notice that you won't have much left to do or to purchase to finish

your new airplane. The Mini-Max EP includes a 280 size motor with a gear box, a propeller, threaded wire

pushrods, clevises, control horns, a prebent landing gear wire, custom lightweight wheels and a colorful

decal sheet.

We hope you enjoy your new Wattage Mini-Max EP as much as we have enjoyed designing and

building it for you. If you have any questions or comments, please feel free to contact us. We have also

included a product survey in the back of this manual. After you have finished assembling the Mini-Max EP,

please take a moment to fill it out and send it to us. We always enjoy hearing any comments or suggestions

that you may have.

TABLE OF CONTENTS

SAFETY WARNING

This R/C airplane is not a toy! If misused, it can cause serious bodily injury and/or damage to property. Fly only in open

areas and preferably at a dedicated R/C flying site. We suggest having a qualified instructor carefully inspect your

airplane before its first flight. Please carefully read and follow all instructions included with this airplane, your radio

control system and electronic speed control.

OUR GUARANTEE

Wattage guarantees this kit to be free from defects in both material and workmanship, at the date of purchase. This

does not cover any component parts damaged by use, misuse or modification. In no case shall Wattage's liability

exceed the original cost of the purchased kit.

In that Wattage has no control over the final assembly or material used for final assembly, no liability shall be

assumed for any damage resulting from the use by the user of the final user-assembled product. By the act of using

the final user-assembled product, the user accepts all resulting liability.

Safety Warning...............................................................2

Our Recommendations...................................................3

Mini-Max EP Setup Information ...................................4

Additional Items Required .............................................5

Tools and Supplies Required .........................................5

Metric Conversion Chart................................................5

Kit Contents....................................................................6

Replacement Parts ..........................................................6

Fuselage Assembly ........................................................7

Installing the Truss Decal ........................................7

Installing the Fuselage Reinforcement Board .........7

Installing the Wing Dowels .....................................8

Tail Surfaces ...................................................................8

Hinging the Elevator................................................8

Mounting the Horizontal Stabilizer .........................9

Hinging the Rudder..................................................9

Mounting the Vertical Stabilizer..............................9

Installing the Control Horns ..................................10

Pushrod Installation .....................................................10

Installing the Servos ..............................................10

Installing the Pushrods...........................................10

Motor Installation.........................................................11

Assembling the Gear Box......................................11

Installing the Gearbox Assembly ..........................12

Landing Gear................................................................12

Installing the Wheels .............................................12

Wing Assembly ............................................................13

Trimming the Plastic Parts.....................................13

Joining the Wing Panels ........................................13

Installing the Wing Dowels ...................................14

Mounting the Wing ................................................15

Final Assembly.............................................................15

Installing the Propeller...........................................15

Installing the Receiver ...........................................15

Installing the ESC ..................................................15

Installing the Flight Battery ...................................16

Installing the Pilot Figure ......................................16

Applying the Decals ..............................................16

Balancing......................................................................17

Balancing the Mini-Max EP ..................................17

Control Throws ............................................................17

Launching the Mini-Max EP .......................................17

Safety............................................................................17

Glossary of Terms ........................................................18

Product Evaluation Sheet.............................................19

This instruction manual is designed to guide you through the entire final assembly process of your new Wattage

Mini-Max EP in the least amount of time possible. Along the way you'll learn how to properly assemble your new

airplane and also learn assembly tips that will help you in the future. We have listed some of our recommendations

below. Please read through them before going any further.

The Mini-Max EP is constructed of Closed Cell sheet foam. It is very important that you use no

solvents, Cyanoacrylate (C/A) glue, or paint that can damage foam. If any of these chemicals

comes in contact with the foam parts, the parts will be destroyed and will not be covered under

warranty. Use only epoxy where glue is required. If you decide to add painted details to the Mini-

Max EP, use acrylic-based paints and always test the paint on a scrap piece first.

✔ Please read through each step before starting as-

sembly. You should find the layout very complete and

simple. Our goal is to guide you through assembly

without any of the headaches and hassles you might

expect.

✔ There are check boxes next to each step. After you

complete a step, check off the box. This will help you

keep from losing your place.

✔ Cover your work table with brown paper or a soft

cloth, both to protect the work table and to protect the

individual parts.

✔ Keep a couple of small bowls or jars handy to put

the small parts in after you open the accessory bags.

✔ We have included a glossary of terms beginning

on page # 18. Check it out if you come across a term

that is unfamiliar to you.

✔ We're all excited to get a new airplane in the air,

but take your time. This will ensure you build a straight,

strong and great flying airplane.

✔ If you come across this symbol

☛

, it means that

this is an important point or an assembly hint.

If you should find a part missing or damaged, or have any questions about assembly, please

Wattage Customer Care

18480 Bandilier Circle

Fountain Valley CA 92728

Phone: (714) 963-0329 Fax: (714) 964-6236 E-mail: service@globalhobby.net

The following section describes our general recommendations to help you in deciding which types of accessories to

purchase for your new Wattage Mini-Max EP. We have tested all of these items with the airplane and found that these

products will offer the best in performance, reliability and economy.

OUR RECOMMENDATIONS

The Mini-Max EP will require a minimum 3 channel radio control system with two micro servos and a micro or mini

receiver. The radio system we recommend using is the Hitec Focus 3 FM radio with a Hitec Micro 555 receiver and two

HS-55 Micro servos. The Hitec Focus 3 AM system with a Hitec HAS-3MB receiver will also work well. In this case

though, you will need to purchase two after-market micro servos - either Cirrus CS-21 Sub-Mirco servos (P/N 444227),

Hitec HS-55 Micro servos (P/N 759257) or Cirrus CS-10 Super-Micro servos (P/N 444052).

If you want to purchase a radio system that will be more upgradeable in the future, the four channel Hitec Flash 4XG

would be a good choice. This radio includes a Hitec Micro 555 receiver; however, you will need to purchase two after-

market micro servos - either Cirrus CS-21 Sub-Mirco servos (P/N 444227), Hitec HS-55 Micro servos (P/N 759257) or

Cirrus CS-10 Super-Micro servos (P/N 444052).

If you already have a standard sized radio system, you will need to purchase an after-market mini or micro receiver and

two micro servos. If you need to purchase these items we recommend using the Hitec Micro 555 receiver (P/N 759118)

and either two Cirrus CS-21 Sub-Mirco servos (P/N 444227), Hitec HS-55 Micro servos (P/N 759257) or Cirrus CS-10

Super-Micro servos (P/N 444052).

RADIO CONTROL SYSTEM

Continued on Next Page

To operate the motor, we suggest using a proportional electronic speed control (ESC) that features battery eliminator

circuitry (BEC) and auto-cutoff. BEC allows you to eliminate the receiver battery and uses the flight battery to control

both the motor and the radio system. Eliminating the receiver battery provides a great weight savings which effectively

increases performance. The auto-cutoff feature turns off the motor when the voltage in the battery drops too low to

operate the radio system safely. This guarantees safe operation throughout the entire flight. To obtain these features, we

suggest using the Wattage IC-5A ESC (P/N 128482). This ESC is a high frequency controller that is microprocessor-

controlled for linear throttle response and features no-hassle digital setup. It is very small and light, which will result in

an overall increase in the performance of the airplane.

The battery you choose should be a 6 cell (7.2Volt) or 7 cell (8.4Volt) 270Mah Nickel Cadmium (NiCD) battery pack

(P/N 128516 or 128517) or a 6 cell or 7 cell 650Mah Nickel Metal Hydride (NiMH) battery pack (P/N 128526 or

128527). The 7 cell battery packs will provide more power, resulting in higher speed and better climb, but they weigh

more than the 6 cell battery packs. The Nickel Metal Hydride battery packs will give you about 50% longer run-time,

but not quite as much overall power.

Battery Warning!

To ensure extended battery life and the best performance from your batteries, the 270Mah NiCD batteries listed

above should be charged at no more than .6amps and the 650Mah NiMH batteries listed above should be charged at no

more than 1 amp. Always allow the battery to cool before recharging. Never charge the battery when it is hot.

ELECTRONIC SPEED CONTROL

FLIGHT BATTERY

Because the flight battery is small and it powers both the motor and the radio system, we suggest using an Automatic

Peak Charger to charge the flight battery. A good choice would be to use the Promax Activator Digital Peak Charger

(P/N 885560). It is vital to the Mini-Max EP's flying performance that the flight battery be fully charged every flight,

so using a peak charger is very important.

BATTERY CHARGER

Mini-Max EP Setup Information

The Mini-Max EP can be set up to be flown either indoors, such as in a large gymnasium, or outdoors in a small park or

field - even in your backyard. Depending on where you will be flying, you might want to adjust the setup to meet your

needs. Below are our recommendations direct from the Wattage Flight Test Team.

For Indoor Flight

For indoor flying it is very important that the Mini-Max EP be assembled using the lightest-weight accessories avail-

able. The less the airplane weighs the slower it can fly - which is good if you're indoors. We strongly suggest using the

very lightweight Cirrus CS-10 Super-Micro servos (P/N 444052), the Hitec Feather FM Micro receiver (P/N 759126)

and either the Wattage 6 cell 270Mah NiCD flight battery (P/N 128516) or the Wattage 6 cell 650Mah NiMH flight

battery (P/N 128526). This combination will provide excellent indoor flying performance.

For Outdoor Flight

If you're going to be flying outdoors you may want to set up the Mini-Max to be more aerobatic. While you still want

to keep the airplane as light as possible, weight is not quite as critical as for indoor flying. For outdoor flight a good

setup to use is the lightweight Cirrus CS-21 servos (P/N 444227), the Hitec 555 Micro receiver (P/N 759118) and the

Wattage 7 Cell 650Mah NiMH flight Battery (P/N 128527). This combination will provide excellent flight times with

the capabilities to do some aerobatics.

Important

Remember why you bought the Mini-Max EP? It was to have fun! The recommendations we've provided are not set in

stone. They are here to give you a good, proven starting point. There are numerous combinations of products that will

work equally well - there are too many to list here. Feel free to experiment with the Mini-Max EP and have fun!

ADDITIONAL ITEMS REQUIRED

❑ {1} Hitec Focus 3 AM Radio System

❑ {2} Cirrus CS-21 Micro Servos # 444227

❑ {1} Wattage IC-5A ESC # 128482

❑ {1} Wattage 6C 270Mah NiCD Battery # 128516

❑ {1} Promax Activator Digital Charger # 885650

❑ {1} Trinity AA Batteries - 8 Pack # 837801

OPTIONAL ITEMS

TOOLS AND SUPPLIES REQUIRED

❑ Kwik Bond 5 Minute Epoxy # 887560

❑ # 0 Phillips Head Screwdriver

❑ # 1 Phillips Head Screwdriver

❑ Excel Modeling Knife # 692801

❑ Adjustable Wrench

❑ Needle Nose Pliers

❑ Wire Cutters

❑ Magnum Z-Bend Pliers # 237473

❑ Electric or Hand Drill

❑ Assorted Drill Bits

❑ Ruler

❑ {1} Hitec Flash 4XG FM Micro Radio System

❑ {1} Hitec Feather Micro Receiver # 759126

❑ {1} Wattage 7C 270Mah NiCD Battery # 128517

❑ {1} Wattage 6C 650Mah NiMH Battery # 128526

❑ {1} Wattage 7C 650Mah NiMH Battery # 128528

❑ Builder's Triangle

❑ 220 Grit Sandpaper w/Sanding Block

❑ Pencil

❑ Scissors

❑ Rubbing Alcohol

❑ Paper Towels

❑ NHP Epoxy Mixing Sticks # 864204

❑ NHP Epoxy Mixing Cups # 864205

❑ K&S 30 Watt Soldering Iron # 598120

❑ Kester Solder # 398505

IMPORTANT

The part number shown for the Cirrus servos is compatible with Hitec and JR radio systems. The part number for the

Hitec Feather Micro receiver is compatible with Hitec and Futaba radio systems. These items are also available with

plugs that are compatible with other radio systems. Please check with your dealer for those part numbers. The Hitec

Feather receiver does not come with a crystal so you will need to purchase the appropriate crystal separately. The

Feather receiver uses single conversion, narrow band crystals and has limited range.

The 650Mah NiMH batteries listed above come with a Tamiya style battery connector. The IC-5A ESC comes with a

BEC style battery connector. If you don't want to solder a new connector onto the flight battery, you can purchase and

use a Wattage Tamiya - BEC adapter (P/N 131153).

To convert inches into millimeters: Inches x 25.4 = mm

1/64" = .4mm

1/32" = .8mm

1/16" = 1.6mm

3/32" = 2.4mm

1/8" = 3.2mm

5/32" = 4.0mm

3/16" = 4.8mm

1/4" = 6.4mm

3/8" = 9.5mm

1/2" = 12.7mm

5/8" = 15.9mm

3/4" = 19.0mm

1" = 25.4mm

2" = 50.8mm

3" = 76.2mm

6" = 152.4mm

12" = 304.8mm

18" = 457.2mm

21" = 533.4mm

24" = 609.6mm

30" = 762.0mm

36" = 914.4mm

METRIC CONVERSION CHART

The soldering iron and solder listed above are optional. Depending on the ESC and flight battery you have chosen to

use, they may not have plugs that are compatible with the plug that comes preinstalled on the motor. If this is the case

you will need to solder a compatible plug onto the motor.

KIT CONTENTS

Below we have organized the parts as they come out of the box for easier identification during assembly. Before you

begin assembly, group the parts like we list them. This will ensure that you have all of the parts before you begin assembly

and it will also help you become familiar with each part.

If you find a part missing or damaged please call us at 1-714-963-0329 or send us an email at service@globalhobby.com

AIRFRAME ASSEMBLIES

❑ {1} Foam Fuselage Assembly

❑ {1} Molded Foam Right Wing Panel

❑ {1} Molded Foam Left Wing Panel

❑ {1} Foam Horizontal Stabilizer w/Elevator

❑ {1} Foam Vertical Stabilizer w/Rudder

❑ {1} Molded Plastic Wing Mount

❑ {1} Molded Plastic Wing Brace

MOTOR & GEAR BOX ASSEMBLY

❑ {1} 280 Size Motor w/Pinion Gear

❑ {1} Molded Gear Box Front w/Bushings

❑ {1} Molded Gear Box Back

❑ {1} 7.5 x 5 Nylon Propeller

❑ {1} Propeller Shaft w/Nylon Gear

❑ {2} 3mm Hex Nuts

❑ {1} 3mm Flat Washer

❑ {5} 2.5mm x 9mm Wood Screws

❑ {1} 3mm x 10mm Self-Tapping Screws

CONTROL ASSEMBLIES

❑ {2} 1.5mm x 400mm Threaded Pushrod Wires

❑ {2} Nylon Control Horns w/Backplates

❑ {2} Nylon Clevises

MISCELLANEOUS ITEMS

LANDING GEAR ASSEMBLY

❑ {1} Prebent Landing Gear Wire

❑ {2} Molded Plastic Wheels

❑ {2} Molded Plastic Wheel Retainers

❑ {1} 3mm x 70mm Dowel

❑ {1} 3mm x 60mm Dowel

❑ {2} 4mm x 235mm Dowels

❑ {1} 37mm x 50mm Sheet-Foam

❑ {1} Fuselage Reinforcement Board

❑ {2} Double Sided Tape

❑ {1} Velcro

❑ {2} Rubber Bands

❑ {1} Decal Sheet

Wattage carries a complete line of replacement parts for your Mini-Max EP. Listed below are the replacement parts that

are available along with their respective part numbers for easy ordering convenience. These replacement parts can be

ordered through your local dealer or directly from Wattage by calling 1-714-963-0329.

REPLACEMENT PARTS

Fuselage Set - 145332

Wing Set - 145333

Stabilizer Set - 145334

Landing Gear Set - 145336

Control Linkage Set - 145327

Decal Sheet - 145337

Instruction Manual - 145331

Gear Box Only (2.5:1) - 131372

7.5 x 5 Nylon Propeller - 131381

280 Size Motor - 131336

Gear Box Complete w/Prop - 145338

FUSELAGE ASSEMBLY

❑ Kwik Bond 5 Minute Epoxy

❑ Excel Modeling Knife

❑ 1/8" Drill Bit

❑ Ruler

❑ Pencil

❑ Scissors

❑ Rubbing Alcohol

❑ Paper Towels

❑ NHP Epoxy Mixing Sticks

❑ NHP Epoxy Mixing Cups

ITEMS REQUIRED

❑ {1} Foam Fuselage Assembly

❑ {1} 3mm x 70mm Dowel

❑ {1} 3mm x 60mm Dowel

❑ {1} Fuselage Reinforcement Board

❑ {1} Decal Sheet

TOOLS AND SUPPLIES REQUIRED

INSTALLING THE TRUSS DECAL

❑ 1) Using a pair of scissors, cut out the fuselage truss

decal along its outer edges. See photo # 1 below.

Photo # 1

❑ 2) Carefully apply the decal to the fuselage, making

sure that the alignment marks at both the front and the back

of the decal line up with the edges of the fuselage. The

back edge of the decal should be 2-1/2" in front of the back

edge of the fuselage. See photo # 2 below.

Photo # 2

☛

Rub the decal down completely to remove any air

bubbles or wrinkles, and to make sure that the decal is

stuck firmly to the fuselage.

INSTALLING THE

FUSELAGE REINFORCEMENT BOARD

❑ 3) Using the tip of your modeling knife, carefully

remove the die-cut pieces out of both the middle and the

outer edges of the fuselage reinforcement board.

❑ 4) Carefully bend each side of the reinforcement

board down at a 90º angle along the two scribe lines. See

photo # 3 below.

Photo # 3

❑ 5) Remove the protective backing from the rein-

forcement board and carefully adhere the reinforcement

board to the fuselage. To align it properly, the front edge

of the board should be even with the back of the ply-

wood motor plate and the sides of the board should follow

the sides of the fuselage. See photo # 4 below.

Photo # 4

❑ 6) Using a modeling knife, carefully cut away and

remove the foam from within the three cutouts in the

reinforcement board. See photo # 5 below.

Photo # 5

INSTALLING THE WING DOWELS

❑ 7) Using a 1/8" drill bit, drill four holes through

the fuselage sides using the die-cut holes in the sides of

the fuselage reinforcement board for reference. See

photo # 6 below.

Photo # 6

☛

To prevent tearing up the foam, don't drill the hole

using an electric drill. It is better to use your fingers to

slowly twist the drill bit.

❑ 8) Test fit the two dowels into the fuselage. The

3mm x 70mm dowel is installed through the forward holes

and the 3mm x 60mm dowel is installed through the rear

holes. Adjust both dowels so that they are centered in the

fuselage. See photo # 7 below.

Photo # 7

❑ 9) Remove both dowels and mix a small quantity

of Kwik Bond 5 Minute Epoxy. Apply a thin layer of

epoxy inside each of the four holes.

❑ 10) Slide the dowels back into place and realign

them. Remove any excess epoxy using a paper towel

and rubbing alcohol, and set the fuselage aside until the

epoxy sets up.

TAIL SURFACES

❑ Kwik Bond 5 Minute Epoxy

❑ Excel Modeling Knife

❑ Ruler

❑ Builder's Triangle

❑ 220 Grit Sandpaper w/Sanding Block

❑ Pencil

❑ Scissors

❑ Rubbing Alcohol

❑ Paper Towels

❑ NHP Epoxy Mixing Sticks

❑ NHP Epoxy Mixing Cups

ITEMS REQUIRED

❑ {1} Foam Horizontal Stabilizer w/Elevator

❑ {1} Foam Vertical Stabilizer w/Rudder

❑ {2} Nylon Control Horns w/Backplates

❑ {1} Decal Sheet

TOOLS AND SUPPLIES REQUIRED

HINGING THE ELEVATOR

Continued at Top of Page

❑ 1) Using a ruler and a modeling knife, carefully cut

out the clear elevator hinge from the decal sheet.

❑ 2) Hinge the elevator to the horizontal stabilizer

using the clear decal. Apply the hinge to the top of the

parts and make sure there is a 1/16" gap between the two

parts. See photo # 8 below.

Photo # 8

☛

Use the guide marks on the ends of the hinge decal to

help you set the proper hinge gap.

❑ 3) Using 220 grit sandpaper with a sanding block,

lightly sand the edges of the stabilizer and the elevator

smooth and even.

❑ 4) Using the tip of your modeling knife, remove the

two die-cut foam pieces. See photo # 9 below.

Photo # 9

❑ 5) Using a ruler and a pencil, draw a centerline

across the top of the horizontal stabilizer. The line should

be perpendicular to the hinge line. See photo # 10 below.

Photo # 10

❑ 6) Set the horizontal stabilizer assembly on top of

the fuselage. To align it properly, the trailing edge of the

stabilizer (not the elevator) should be even with the back

edge of the fuselage and the centerline you drew on top of

the stabilizer should be centered over the middle of the

fuselage. See photo # 11 below.

❑ 7) When satisfied with the alignment, use a pencil

to draw two lines on the bottom of the stabilizer (one on

each side) where the stabilizer meets the fuselage sides.

See photo # 12 below.

Photo # 11

Photo # 12

MOUNTING THE

HORIZONTAL STABILIZER

❑ 8) Mix a small quantity of Kwik Bond 5 Minute

Epoxy and apply a thin layer to only the bottom of the

stabilizer between the two lines you drew.

❑ 9) Set the stabilizer back into place and realign it.

Remove any excess epoxy using a paper towel and rub-

bing alcohol, and hold the stabilizer firmly in place until

the epoxy sets up.

HINGING THE RUDDER

❑ 10) Using the tip of your modeling knife, carefully

remove the piece of die-cut foam from the rudder. See

photo # 13 below.

❑ 11) Using a pair of scissors, carefully cut out the

right and left rudder decals from the decal sheet. Notice

that the left-side decal acts as the rudder hinge, too.

❑ 12) Carefully apply the right-side decal onto the

rudder. After the decal is in place, use a pair of scissors to

trim the decal flush with the edges of the rudder.

❑ 13) Hinge the rudder to the vertical stabilizer using

the left side decal, making sure there is a 1/16" hinge gap

between the two parts. See photo # 14 below.

Photo # 13

Photo # 14

❑ 14) After the decal is in place, use a pair of scissors

to trim the decal flush with the edges of the rudder. After

you've trimmed the decal, use 220 grit sandpaper with a

sanding block to lightly sand the edges of the stabilizer

and the rudder smooth and even.

❑ 15) Using a modeling knife, cut away and remove

the decal from over both sides of the die-cut hole in the

rudder.

MOUNTING THE

VERTICAL STABILIZER

❑ 16) Set the vertical stabilizer assembly on top of the

horizontal stabilizer. To align it properly, the tab in the

vertical stabilizer should fit into the slot in the horizontal

stabilizer and the leading edge of the vertical stabilizer

should be even with the leading edge of the horizontal

stabilizer.

❑ 17) While holding the vertical stabilizer in place,

use a builder's triangle to check to ensure that it is aligned

90º to the horizontal stabilizer. See figure # 1 below.

Figure # 1

❑ 18) When satisfied with the alignment, remove the

vertical stabilizer. Mix a small quantity of Kwik Bond 5

Minute Epoxy and apply a thin layer to only the bottom

edge of the vertical stabilizer.

❑ 19) Set the stabilizer back into place and realign it,

double checking that it is 90º to the horizontal stabilizer.

Remove any excess epoxy using a paper towel and rub-

bing alcohol, and hold the stabilizer in place until the epoxy

sets up. See photo # 15 below.

Photo # 15

INSTALLING THE CONTROL HORNS

❑ 20) Push one control horn through each die-cut slot

in the rudder and the elevator. The tip of the elevator

control horn should face the top of the elevator and the tip

of the rudder control horn should face the side opposite

the elevator control horn.

❑ 21) Making sure that the flat portion of the backplates

face away from the control surfaces, push the backplates

over the ends of the control horns until you hear them

"click" firmly into place. See photo # 16 below.

Photo # 16

PUSHROD INSTALLATION

❑ Excel Modeling Knife

❑ Needle Nose Pliers

❑ Wire Cutters

❑ Magnum Z-Bend Pliers

❑ Electric or Hand Drill

❑ 1/16" Drill Bit

❑ Pencil

ITEMS REQUIRED

❑ {2} 1.5mm x 400mm Threaded Pushrod Wires

❑ {2} Nylon Clevises

TOOLS AND SUPPLIES REQUIRED

INSTALLING THE SERVOS

❑ 1) Install the rubber grommets and brass collets onto

each of the servo mounting lugs.

❑ 2) Test fit your two micro servos into the rear hole

in the servo tray. If necessary, use a modeling knife to

enlarge the hole in the servo tray to accommodate the two

servos. The servos should fit tightly in the servo tray.

See photo # 17 below.

☛

Both of the servos' output shafts should face toward

the front of the fuselage.

❑ 3) Mount the servos into the servo tray using the

servo mounting screws provided with your servos. To

make it easier to install the screws, use the tip of your

modeling knife to make small pilot holes in the rein-

forcement board.

Photo # 17

❑ 4) Plug the elevator and rudder servos into their

proper slots in the receiver. Plug the ESC lead into the

receiver and the flight battery into the ESC . Turn on the

radio system and center both of the servos using the trim

levers on the transmitter.

❑ 5) Thread one nylon clevis onto each of the two

1.5mm x 400mm threaded pushrod wires. Thread the

clevises on far enough to leave room for adjustments later.

INSTALLING THE PUSHRODS

❑ 6) Carefully snap the clevis on one pushrod into the

elevator control horn. See photo # 18 below.

Photo # 18

❑ 7) Place a "single arm" servo horn onto the eleva-

tor servo, making sure that the servo horn is centered and

points toward the outside of the fuselage. The arm should

have at least three holes in it.

❑ 8) With both the servo horn and the elevator cen-

tered, use a pencil to draw a mark on the pushrod wire

where it crosses the third hole out from the center of the

servo horn. See photo # 19 below.

❑ 9) Using Magnum Z-Bend Pliers, make a Z-Bend

in the pushrod wire at the mark you drew. Use wire

cutters to remove the excess wire.

❑ 10) Remove the servo horn, attach it to the Z-Bend,

then attach the servo horn to the servo, making sure it's

centered. Install and tighten the servo horn retaining screw,

provided with your servo, to secure the servo horn into

place. See photo # 20 below.

Photo # 19

Photo # 20

❑ 11) Install the rudder pushrod wire using the same

technique as with the elevator pushrod wire. The Z-Bend

should be installed into the third hole out from the center

of the servo horn as well. See photo # 21 below.

☛

You will need to enlarge the third hole out in the servo

arm using a 1/16" drill bit, so that the pushrod wire will

fit through.

Photo # 21

❑ 12) Double check that the elevator and rudder are

still centered. If they are out of adjustment, remove the

clevises and readjust them until you are satisfied with the

alignment.

MOTOR INSTALLATION

ITEMS REQUIRED

❑ {1} 280 Size Motor w/Pinion Gear

❑ {1} Molded Gear Box Front w/Bushings

❑ {1} Molded Gear Box Back

❑ {1} Propeller Shaft w/Nylon Gear

❑ {2} 3mm Hex Nuts

❑ {1} 3mm Flat Washer

❑ {5} 2.5mm x 9mm Wood Screws

❑ {1} 3mm x 10mm Self-Tapping Screws

❑ {1} Prebent Landing Gear Wire

❑ # 1 Phillips Head Screwdriver

❑ Adjustable Wrench

❑ Electric or Hand Drill

❑ 1/16" Drill Bit

❑ Pencil

TOOLS AND SUPPLIES REQUIRED

ASSEMBLING THE GEAR BOX

❑ 1) Slide the propeller shaft through the two prein-

stalled bushings in the front gear box half and push it

forward until the nylon gear is up against the back of the

gear box.

❑ 2) Slide the motor into place, making sure that the

pinion gear engages the nylon gear on the propeller shaft.

❑ 3) Slide the back half of the gear box over the back

of the motor and use two 2.5mm x 9mm wood screws

and one 3mm x 10mm self-tapping screw to secure the

two halves together. The two wood screws should be

installed in the two lower mounting holes and the self-

tapping screw should be installed in the upper mounting

hole. See photo # 22 below.

Photo # 22

☛

It is normal for there to be front-to-back play in the

propeller shaft. After installing the propeller the play will

go away.

❑ 4) Carefully press the landing gear wire into the

molded groove in the back of the gear box assembly. See

photo # 23 below.

INSTALLING THE GEAR BOX ASSEMBLY

Photo # 23

❑ 5) Slide the motor wires into the precut hole in the

front of the fuselage and push the motor assembly up

against the plywood motor plate.

❑ 6) Align the bottom of the gear box assembly with

the bottom of the motor plate and use a pencil to mark the

locations of the three mounting holes onto the motor plate.

See photo # 24 below.

Photo # 24

❑ 7) Remove the gearbox assembly and set it aside.

Using a drill with a 1/16" drill bit, drill pilot holes through

the motor plate at each of the three marks you drew.

❑ 8) Set the gearbox assembly back into place and

realign it. Install and tighten three 2.5mm x 9mm wood

screws to hold the gearbox assembly securely to the fu-

selage. See photo # 25 below.

Photo # 25

LANDING GEAR

ITEMS REQUIRED

❑ {2} Molded Plastic Wheels

❑ {2} Molded Plastic Wheel Retainers

❑ Needle Nose Pliers

TOOLS AND SUPPLIES REQUIRED

INSTALLING THE WHEELS

❑ 1) Slide one wheel onto one of the axles. Using

needle nose pliers, carefully squeeze one molded plastic

wheel retainer onto the axle to secure the wheel in place.

See photo # 26 below.

Photo # 26

☛

Double check that the wheel spins without binding.

If the wheel does bind, carefully pull the retainer just far

enough away from the wheel to prevent the binding.

❑ 2) Repeat step # 1 to install the second wheel and

wheel retainer.

WING ASSEMBLY

ITEMS REQUIRED

❑ {1} Molded Foam Right Wing Panel

❑ {1} Molded Foam Left Wing Panel

❑ {1} Molded Plastic Wing Mount

❑ {1} Molded Plastic Wing Brace

❑ {2} 4mm x 235mm Dowels

❑ {2} Double-Sided Tape

❑ {2} Rubber Bands

❑ {1} Decal Sheet

❑ Excel Modeling Knife

❑ Ruler

❑ 220 Grit Sandpaper w/Sanding Block

❑ Scissors

TOOLS AND SUPPLIES REQUIRED

TRIMMING THE PLASTIC PARTS

❑ 1) Using a pair of scissors, carefully cut out the base

of the plastic wing mount along the molded scribe line.

See photo # 27 below.

Photo # 27

❑ 2) Using a pair of scissors, carefully cut away and

remove the plastic from over the two molded pushrod exit

slots in the back of the wing mount. See photo # 28 below.

Photo # 28

❑ 3) Using 220 grit sandpaper with a sanding block,

sand the edges of the plastic wing mount smooth and

straight.

❑ 4) Using a pair of scissors, carefully cut out the

molded plastic wing brace along its top edge. Also cut

the brace along the two molded scribe lines in the top of

the brace. See photo # 29 below.

Photo # 29

❑ 5) Using 220 grit sandpaper with a sanding block,

sand the edges of the plastic wing brace smooth and

straight.

JOINING THE WING PANELS

❑ 6) Use a pair of scissors to cut one 3/8" x 6-1/2"

strip out of each piece of the double-sided tape provided.

❑ 7) Remove the protective backing from one side of

each strip of the double-sided tape. Carefully stick the

two pieces of tape to the top of the plastic wing mount.

See photo # 30 below.

Photo # 30

❑ 8) From the remaining two pieces of double-sided

tape, cut one 1-5/8" x 6-3/4" strip out of each piece.

❑ 9) Remove the protective backing from one side of

each strip and carefully stick the two pieces of tape to the

bottom of the plastic wing brace. See photo # 31 below.

Photo # 31

❑ 10) Using a pair of scissors, cut out a piece of

double-sided tape to the approximate shape of the wing

root. Remove the protective backing from one side of the

tape and apply the tape to the root section of one wing

half. See photo # 32 below.

Photo # 32

❑ 11) Remove the remaining piece of protective back-

ing from the double-sided tape and carefully press the two

wing halves together, being careful to make sure that the

leading and trailing edges line up. Don't worry about the

dihedral angle at this time because this is just temporary.

See photo # 33 below.

Photo # 33

❑ 12) Remove the protective backing from the two

pieces of double-sided tape on the plastic wing mount.

Carefully set the wing into the mount, making sure that

the centerline of the wing is centered in the mount. Again,

don't worry about the dihedral angle at this point. See

photo # 34 below.

Photo # 34

❑ 13) After you are satisfied with the alignment of the

wing, carefully push the wing firmly into place to make

sure it is firmly secured to the double-sided tape. Again,

don't worry about the dihedral angle. The proper dihe-

dral angle will be set in the next few steps.

❑ 14) Remove the protective backing from the two

pieces of double-sided tape on the bottom of the plastic

wing brace.

☛

Before proceeding with the next step, keep this in

mind: the front edge of the wing brace should be even

with the leading edge of the wing. It should not overlap

the front of the wing mount. Any excess that hangs past

the trailing edge of the wing will be trimmed off later.

❑ 15) With the wing upright on your work table, care-

fully set the plastic wing brace on top of the wing, aligning

the centerline marks at the front and back of the brace

with the centerline of the wing. Very carefully push the

brace down firmly to sandwich the wing between the brace

and the wing mount. See photo # 35 below.

Photo # 35

☛

The correct dihedral angle will automatically be set

after sandwiching the wing between the wing brace and

the wing mount.

❑ 16) When satisfied with the wing's alignment, use a

pair of scissors to carefully trim the wing brace flush with

both the leading and trailing edges of the wing.

INSTALLING THE WING DOWELS

❑ 17) Using a ruler and a modeling knife, cut out the

clear wing dowel hold-down strips from the decal sheet.

❑ 18) Secure one dowel onto the leading edge of each

half of the wing using one clear hold-down strip each.

The inside edge of each dowel should be pushed against

the side of the plastic wing mount and both dowels should

be installed on the very front of the leading edge, not the

top or bottom of it. See photo # 36 below.

Photo # 36

MOUNTING THE WING

❑ 19) Set the wing assembly onto the fuselage. To

align it properly, the front of the wing mount should be

pushed up against the back of the gear box and centered

on the fuselage.

☛

Depending on the positions of the elevator and rud-

der pushrods, you may need to enlarge the slots in the

back of the wing mount to clear them. You may also need

to cut the servo arms shorter so they don't hit the sides of

the wing mount.

❑ 20) When satisfied with the alignment, hold the wing

in place using two rubber bands. See photo # 37 below.

Photo # 37

FINAL ASSEMBLY

ITEMS REQUIRED

❑ {1} 7.5 x 5 Nylon Propeller

❑ {2} 3mm Hex Nuts

❑ {1} 3mm Flat Washer

❑ {1} 37mm x 50mm Sheet-Foam

❑ {1} Velcro

❑ {1} Decal Sheet

❑ Excel Modeling Knife

❑ Adjustable Wrench

❑ Scissors

TOOLS AND SUPPLIES REQUIRED

INSTALLING THE PROPELLER

❑ 1) Thread one 3mm hex nut onto the propeller shaft

and tighten it by hand until it will not thread on any further.

❑ 2) Slide the propeller onto the propeller shaft,

making sure that the back of the propeller slides firmly

over the hex nut.

☛

The back of the propeller is molded to fit over the

hex nut.

❑ 3) Slide the 3mm flat washer up against the pro-

peller and thread on the second 3mm hex nut. Tighten

the hex nut firmly, using an adjustable wrench, to hold

the propeller in place. See photo # 38 below.

Photo # 38

INSTALLING THE RECEIVER

❑ 4) Plug the elevator and rudder servo leads into their

proper slots in the receiver.

❑ 5) Uncoil the receiver antenna and feed it into the

hole in front of the servos, down through the inside of the

fuselage and out the back.

❑ 6) Mount the receiver inside the hole in front of the

servos using a couple of pieces of double-sided tape. De-

pending on the size of the receiver you're using, you may

need to enlarge the cutout so that the receiver will fit par-

tially down into the fuselage. See photo # 39 below.

☛

If you're using the Hitec HAS-3MB receiver and the

Wattage 6 or 7 cell 270Mah NiCD flight battery, you will

need to move the receiver back so that there is room to

install the flight battery. This is shown in the photo above.

Photo # 39

INSTALLING THE ESC

❑ 7) Connect the motor lead on the ESC to the motor

lead on the motor. Run the ESC lead through the front

hole in the fuselage and install it into the proper slot in the

receiver.

☛

If the motor lead on your ESC does not match the

motor lead on the motor, you will need to remove the

motor lead from the motor and replace it with one that is

compatible with your ESC.

❑ 8) Mount the ESC to the inside of the fuselage, right

behind the motor plate. Use a small piece of double-sided

tape to hold the ESC in place. See photo # 40 below.

Photo # 40

INSTALLING THE FLIGHT BATTERY

☛

To reduce the possibility of radio interference, mount

the ESC as far away from the receiver as possible.

☛

The mounting location of the flight battery will de-

pend on which flight battery you decide to use.

❑ 9) If you are using the Wattage 6 or 7 cell 270Mah

NiCD flight battery, mount it on top of the fuselage using

a couple small pieces of Velcro®. See photo # 41 below.

Photo # 41

☛

The location of the different flight batteries shown

above is only approximate. You may need to move the

flight battery fore or aft to balance the airplane when that

is done in the next section.

❑ 10) If you are using the Wattage 6 or 7 cell 650Mah

NiMH flight battery, mount it down in the hole in the front

of the fuselage using a couple small pieces of Velcro®.

See photo # 42 below.

Photo # 42

INSTALLING THE PILOT FIGURE

❑ 11) Using a pair of scissors, carefully cut out each

of the two pilot figure decals along their outer edges.

Apply one decal to one side of the 37mm x 50mm sheet-

foam. See photo # 43 below.

Photo # 43

❑ 12) Using a sharp modeling knife, carefully trim the

sheet-foam along the outer edges of the decal. Apply the

second decal to the opposite side of the sheet-foam.

❑ 13) Mount the pilot on top of the fuselage using a

narrow strip of double-sided tape. See photo # 44 below.

Photo # 44

APPLYING THE DECALS

❑ 14) Working with one decal at a time, use a pair of

scissors and carefully cut out the decal along its outer

edges.

❑ 15) Remove the protective backing from the decal

and apply the decal to the airplane (use the box cover

photos to position the remaining decals). Lightly rub

the decal with a soft cloth to remove any trapped air from

beneath it.

☛

If any air bubbles form in the decal you can "prick"

the bubble with a straight pin to release the air.

❑ 16) Repeat the steps above to apply the remaining

decals. Rub each decal down thoroughly to adhere it into

place.

☛

We strongly suggest cutting two 1/4" diameter air-

intake holes in the front of the plastic wing mount to allow

cool air to pass over the flight battery.

TOOLS AND SUPPLIES REQUIRED

BALANCING

❑ Ruler

❑ Pencil

BALANCING THE MINI-MAX EP

❑ 1) It is critical that your airplane be balanced cor-

rectly. Improper balance will cause your airplane to either

perform poorly or to lose control and crash.

This location is recommended for initial test flying. The

C.G. can be moved fore or aft up to 3/8", but it is not

recommended that the C.G. be located any farther back

than 2-3/4" behind the leading edge of the wing, at the

fuselage sides.

☛

The Mini-Max EP should be balanced with the flight

battery mounted in the fuselage.

❑ 2) Using a ruler and a pencil, measure and mark

the location of the Center of Gravity on both sides of the

fuselage.

❑ 3) With the airplane right side up, place your fin-

gers on the two marks you drew and carefully lift the

airplane. If the nose of the airplane falls, the airplane is

nose heavy. To correct this, move the flight battery back

just far enough to bring the airplane into balance. If the

tail of the airplane falls, the airplane is tail heavy. To

correct this, move the flight battery forward just far

enough to bring the airplane into balance. When bal-

anced correctly, the airplane should sit level or slightly

nose down when you lift it up with your fingers.

☛

Once you have flown and become familiar with the

flight characteristics of the Mini-Max EP, the balance

point (C.G.) can be moved fore or aft up to 3/8" in each

direction to change the flight performance. Moving the

The Center of Gravity is located 2-3/8"

back from the leading edge of the

wing, at the fuselage sides.

balance point back will cause the airplane to be more re-

sponsive, but less stable. Moving the balance point

forward will cause the airplane to be more stable, but less

responsive. Do not fly the Mini-Max EP beyond the

recommended balance range or an uncontrollable

crash could result!

CONTROL THROWS

❑ 1) We recommend setting up the Mini-Max EP us-

ing the control throws listed below. Once you become

familiar with the Mini-Max EP's flying characteristics, feel

free to increase the control throws as necessary.

Measure the control throws from the

widest point of each control surface.

IMPORTANT

So that the Mini-Max EP will fly straight and level the

elevator must be trimmed down 3/8" from center. This

is the "neutral point". The elevator control throws

should be measured from the neutral point.

To hand-launch the Mini-Max EP, gently grasp the fuse-

lage between your thumb and forefingers at the C.G.

location. Hold the airplane above shoulder level and

turn on the motor to full power. With the motor running

at full power, gently toss the Mini-Max EP straight ahead.

Do not throw it up at an angle or throw it hard. Let the

airplane fly straight and level to pick up airspeed, then

climb to your desired altitude. Be careful not to climb

too steeply after hand-launching or you could stall the

airplane.

☛

The Mini-Max EP can be flown in light winds; how-

ever, we don't recommend flying it in the wind until you

have become familiar with its flying characteristics.

LAUNCHING THE MINI-MAX EP

SAFETY

The following are our general guidelines for your safety

and the safety of others. Please read and understand these

safety guidelines before going out to the flying field for

the first time.

❑ 1) Always turn on your transmitter first, then plug

in the flight battery. After you land unplug the flight

battery; only then turn off your transmitter.

TEST FLYING

Elevator: 3/4" up 3/4" down

Rudder: 1" right 1" left

GLOSSARY OF TERMS

Center of Gravity: Most commonly referred to as the

C.G. or balance point, it is the point at which the airplane

is in complete balance in all three axes.

Clevis: Part of the control system, either made out of

nylon or metal. It connects the pushrod wire to the con-

trol horn mounted on the control surface.

Control Horn: Part of the control system, the control

horn is mounted to the control surface. It allows the push-

rod to be connected to the control surface. Almost all

control horns are adjustable to allow for more or less con-

trol surface movement.

Cycling: The act of fully charging and discharging the

flight battery. Cycling the battery increases performance

and duration.

Dihedral: The upward angle of each wing half. Dihe-

dral creates more stability which makes learning to fly

much easier.

Elevator: The elevator is the control surface on the back

of the airplane that moves up and down. This surface

controls pitch.

Epoxy: A two-part glue containing a resin and a hard-

ener. Epoxy is available in several drying times and is

stronger than C/A glue. Epoxy is used in high stress ar-

eas such as where wing halves are joined.

ESC: An acronym for Electronic Speed Control. See

Motor Controller below.

Horizontal Stabilizer: Mounted in the rear of the air-

plane, the stabilizer works with the elevator to control

pitch.

Motor Controller: Usually called an electronic speed

control (ESC), the motor controller controls the speed of

the motor. Motor controllers can also be simple on and

off switches.

Peak Charger: A type of battery charger that uses a mi-

croprocessor to sense when the flight battery is fully

charged. Once peak charged, the charger shuts off so the

battery does not overcharge.

Pushrods: They connect between the control surface and

the servo, transferring the movement of the servo directly

to the control surface.

Receiver: The part of the radio system that receives the

signals from the transmitter.

Rudder: The rudder is the control surface on the back of

the airplane that moves right and left. This causes the

nose of the airplane to yaw right and left.

Servo: The part of the radio system that produces the

movement necessary to move the control surfaces. The

servo includes a small motor, gears and a circuit board.

Transmitter: The part of the radio system that you con-

trol. It transmits the control inputs to the receiver, which

transfers that information to the servos.

Vertical Stabilizer: Mounted on the rear of the airplane,

it works with the rudder to turn the airplane. It also gives

the airplane vertical stability.

Wing Hold Down Dowel: A length of hardwood dowel

or aluminum inserted through the fuselage at the front and

back of the wing saddle. It is an anchor for the rubber

bands that hold the wing onto the fuselage.

Wing Saddle: The portion of the fuselage where the wing

is mounted.

Z-Bend: This is a special bend made in the pushrod wire.

While it cannot improve your ability to make adjustments,

the Z-Bend is the most secure way to attach the pushrod

wire to the servo horn.

❑ 2) Do not test fly your model for the first time with-

out first having it safety-checked by an experienced

modeler.

❑ 3) Do not fly your model higher than approximately

400 feet within 3 miles of an airport without having an

observer with you. The observer should tell you about

any full size aircraft in your vicinity; you should always

give the right of way to full scale aircraft.

❑ 4) When flying at a flying field with established

rules, you should abide by those rules. You should not

deliberately fly your model in a reckless and/or danger-

ous manner.

❑ 5) While flying, you should not deliberately fly be-

hind the flight line. If your model should inadvertently

fly behind the flight line, you should change course im-

mediately.

❑ 6) You should complete a successful range check

of your radio equipment prior to each new day of flying,

or prior to the first flight of a new or repaired model.

❑ 7) You should perform your initial turn after take-

off away from the flightline and/or spectator area.

❑ 8) You should not knowingly operate your R/C ra-

dio system within 3 miles of a preexisting model club

flying field without a frequency sharing agreement with

that club.

Telling us what you like and don't like determines what model kits we make and how we make them. We would

appreciate it if you would take a few minutes of your time to answer the following questions about this kit. Simply

fold this form on the dotted lines, seal with tape and mail it to us. Do not use staples and make sure our address faces

out.

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ODUCT EVODUCT EV

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TION SHEET

1) Kit: Wattage Mini-Max EP Electric

2) Where did you learn about this kit?

❑ Magazine Ads ❑ Friend

❑ Hobby Shop ❑ Other

❑ Internet

3) What influenced you the most to buy this kit?

❑ Magazine Ads ❑ Price

❑ Type of Model ❑ Box Art

❑ Recommendation ❑ Other

❑ Internet

4) Did you have any trouble understanding the

written instructions? If yes, please explain.

❑ Yes ❑ No

________________________________________

5) Did you have any trouble understanding any of

the photographs? If yes, please explain.

❑ Yes ❑ No

________________________________________

6) Were any of the kit parts:

❑ Damaged ❑ Wrong Size

❑ Missing ❑ Wrong Shape

If you checked any of the boxes above, did you

contact our Customer Service Department to

resolve the problem?

❑ Yes ❑ No

7) Was any of the assembly difficult for you? If

yes, please explain.

❑ Yes ❑ No

________________________________________

8) What did you like most about this kit?

❑ Assembly Manual ❑ Parts Fit

❑ Hardware Supplied ❑ Price

❑ Other

________________________________________

9) What did you like least about this kit?

❑ Assembly Manual ❑ Parts Fit

❑ Hardware Supplied ❑ Price

❑ Other

________________________________________

10) Are you satisfied with the finished model? If

no, please explain.

❑ Yes ❑ No

________________________________________

11) How does this kit compare to similar kits by

other manufacturers?

❑ Better ❑ As Good

❑ Not as Good

Additional Comments: ______________________________________________________________________

________________________________________________________________________________________

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WattAge Mini-Max EP Instructions Manual

Brand: WattAge

Model: Mini-Max EP

Category: Toys & accessories

Type: Instructions Manual

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