INSTRUCTIONS FOR FINAL ASSEMBLY Specifications: The Sportsman Aviation F-20 Tigershark 40 ARF is distributed exclusively by Global Hobby Distributors 18480 Bandilier Circle, Fountain Valley, CA 92708 All contents copyright © 2004, Global Hobby Distributors Version V1.0 February 2004 Kit Product Number 127520 ● Wing Span: 47 Inches ● Wing Area: 535 Square Inches ● Length: 54 Inches ● Weight RTF: 5.5 - 6.5 Pounds ● Wing Loading: 23.
TABLE OF CONTENTS Safety Warning ........................................................................... 2 Section 14: Rudder Control System Installation .................... 29 Introduction ................................................................................. 3 Section 15: Elevator Control System Installation ................... 31 Section 1: Our Recommendations ............................................ 4 Section 16: Aileron Control System Installation .....................
INTRODUCTION Thank you for purchasing the Sportsman Aviation F-20 Tigershark 40 ARF. Before completing the final assembly of your new airplane, please carefully read through this instruction manual in its entirety.
SECTION 1: OUR RECOMMENDATIONS This section describes our recommendations to help you in deciding which types of accessories to purchase for your new Sportsman Aviation F-20 Tigershark 40 ARF. Please read through this entire section very carefully. We have provided you with tips and recommendations that, if followed, will result in a great flying airplane. Failure to follow our recommendations may result in a poor flying airplane.
SECTION 2: TOOLS AND SUPPLIES REQUIRED The tools and supplies listed below will be necessary to finish the assembly of your F-20 Tigershark 40 ARF. We suggest having these items on hand before beginning assembly.
KIT CONTENTS, CONTINUED....
SECTION 4: REPLACEMENT PARTS Global stocks a complete line of replacement parts for your Sportsman Aviation F-20 Tigershark 40 ARF. Listed below are the replacement parts that are available along with their respective part numbers for easy ordering convenience. We suggest ordering directly from your local dealer.
SECTION 6: WING ASSEMBLY YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT: ❑ (1) Right Wing Panel w/Aileron ❑ (1) Plywood Wing Joiner (W17) ❑ (1) Left Wing Panel w/Aileron ❑ (1) Balsa Leading Edge Support (W20) YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES: ❑ Kwik Bond 30 Minute Epoxy ❑ Masking Tape ❑ Excel Modeling Knife ❑ Paper Towels ❑ Ruler ❑ Rubbing Alcohol ❑ Pencil ❑ NHP Epoxy Mixing Sticks ❑ 220 Grit Sandpaper w/Sanding Block ❑ NHP Epoxy Mixing Cups STEP 1: ALIGNING THE WING PANELS ❑ Remove
❑ Carefully slide both wing panels together with the wing joiner temporarily installed (without using glue). ✦ IMPORTANT✦ ✦ When the wing joiner is installed, it should not fit tightly into the wing panels. It should actually be slightly loose. This will ensure that when you glue the wing joiner into place epoxy can get into the joints between the wing joiner and the joiner box.
STEP 3: CHECKING THE WING CENTER-SECTION JOINT ❑ Once the epoxy has fully cured, remove the masking tape and double-check the center-section joint. If any gaps are present, mix a small quantity of 30 minute epoxy and carefully fill any remaining gaps. Quickly remove any excess epoxy, using a paper towel and rubbing alcohol, and allow the epoxy to thoroughly cure. ✦ Do not omit this procedure.
❑ Set the fuselage upside down in your airplane stand. Place the wing into the wing saddle, push it forward completely, then push the trailing edge down into place. ☞ Two holes have been predrilled in the forward bulkhead to accept the wing hold-down dowels in the leading edge of the wing.
❑ Set the wing back into the wing saddle and realign it. Again, use masking tape or weights to keep the wing firmly in place and aligned. ❑ Mix a generous amount of 5 minute epoxy and apply a thin layer to the gluing surfaces of the wing fairing. Set the wing fairing back into place and realign it. Remove any excess epoxy, using a paper towel and rubbing alcohol, and hold the wing fairing firmly in place, until the epoxy sets up.
SECTION 8: STABILIZER INSTALLATION YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT: ❑ (1) Horizontal Stabilizer w/Elevator Halves ❑ (1) 2-1/4" Prebent Torque Rod w/Flange Bearing ❑ (1) Vertical Stabilizer w/Rudder ❑ (2) 2-1/2" Prebent Torque Rods w/Flange Bearing YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES: ❑ Kwik Bond 5 Minute Epoxy ❑ Builder's Triangle ❑ Kwik Bond 30 Minute Epoxy ❑ 220 Grit Sandpaper w/Sanding Block ❑ Lightweight Oil or Vaseline ® ❑ Masking Tape ❑ Excel Modeling Knife ❑ Paper To
❑ Slide the horizontal stabilizer into the mounting slot and center it by carefully measuring out from each side of the fuselage to each end of the stabilizer (at the trailing edge only for now). When the stabilizer is centered, both measurements will be equal. ☞ The top of the stabilizer is covered red. ✦ IMPORTANT✦ ✦ The stabilizer should be pushed forward as far as possible. There will be about a 1/8" wide gap between the trailing edge of the stabilizer and the mounting slot.
❑ With the stabilizer properly aligned, use a pencil to draw a line on each side of the stabilizer where it meets the fuselage sides. Do this on both the top and the bottom. STEP 2: MOUNTING THE HORIZONTAL STABILIZER ❑ Remove the stabilizer from the fuselage. ❑ Using a modeling knife, carefully cut away and remove the covering material from between the lines you drew. Do this on both the top and the bottom.
❑ Gently push the nylon bearing into the slot, then slide the torque rod into the fuselage, so that the plain end of the torque rod is near the nylon bearing, as shown. ❑ Test-fit the second elevator torque rod into the right side of the elevator, using the same techniques. Again, don't glue the torque rod into place yet. ❑ Turn the fuselage over and remove the control system hatch cover from the back of the fuselage. ❑ Look inside the hatch. The threaded ends of both torque rods should appear, as shown.
❑ When satisfied with the fit, remove the torque rod from the stabilizer and set it aside for now. ✦ IMPORTANT✦ ✦ Do not glue the torque rod into the stabilizer at this time. If you glue it into place now, you won't be able to mount the stabilizer. ❑ Push the vertical stabilizer down into its mounting slot. To align it properly, it should be pushed down firmly and there should be about a 1/8" wide gap between the trailing edge and the back of the mounting slot.
SECTION 9: CONTROL SURFACE HINGING YOU'LL NEED THE FOLLOWING PARTS FROM THE KIT: ❑ (13) C/A Style Hinges ❑ (3) Nylon Adjustable Control Horns (Small Thread) YOU'LL NEED THE FOLLOWING TOOLS AND SUPPLIES: ❑ Kwik Bond Thin C/A ❑ Waxed Paper ❑ Kwik Bond 5 Minute Epoxy ❑ Paper Towels ❑ Kwik Bond C/A Debonder ❑ Rubbing Alcohol ❑ Lightweight Oil or Vaseline ® ❑ NHP Epoxy Mixing Sticks ❑ Excel Modeling Knife ❑ NHP Epoxy Mixing Cups ❑ 220 Grit Sandpaper w/Sanding Block ✦ WARNING✦ ✦ For flutter-free con
❑ When satisfied with the fit, remove the aileron from the wing, but leave the hinges in the aileron. ❑ Cut out a 1-1/2" square piece of waxed paper. ❑ Slide the waxed paper between the torque rod wire and the trailing edge of the wing. ☞ The waxed paper will prevent epoxy from gluing the torque rod to the trailing edge.
❑ Using a modeling knife, carefully cut away and remove the covering material from over the precut slot in the root end of one elevator half. ☞ Notice that there is a predrilled hole in the slot to accept the elevator torque rod wire. ❑ Push two T-pins through the center of two C/A style elevator hinges. The T-pins will keep the hinges centered while you are hinging the elevator half. ❑ Slide one hinge into each hinge slot in the elevator half, making sure that you push each hinge in up to the T-pins.
❑ Repeat the previous procedures to hinge the second elevator half to the stabilizer, making sure to check the integrity of the hinges after the C/A and epoxy fully cure. STEP 3: HINGING THE RUDDER ❑ Hinge the rudder using the same techniques that you used to hinge the elevator halves. Again, to make it easier to install, thread the nylon adjustable control horn onto the threaded rudder torque rod wire before hinging the rudder. The rudder is hinged using three hinges.
❑ Working with one landing gear wire for now, position two nylon straps over the landing gear wire, equal distances from each end of the wire. ❑ While holding the nylon straps in place, use a pencil to mark the locations of the mounting screws onto the wing. ✦ IMPORTANT✦ ✦ Make sure that the nylon landing gear straps are centered over the landing gear wire when you mark the positions of the mounting screw holes.
❑ Using a modeling knife, cut away and remove the covering material from over the precut nose gear clearance hole in the bottom of the fuselage. The hole is located 5-1/2" behind the firewall and is 3/4" in diameter. ❑ Remove the fuel tank hatch cover from the fuselage and set it aside. ✦ Before continuing, notice that there are two precut flat spots on the nose gear wire that the machine ✦ IMPORTANT✦ screws in the nylon steering arm and one wheel collar tighten against.
STEP 4: INSTALLING THE NOSE GEAR WHEEL ❑ Install the nose gear wheel, using the same techniques you used to install the main gear wheels. ☞ Make sure that the recessed side of the wheel is toward the nylon spacer.
❑ Using a pencil, carefully mark the locations of the engine mounting holes onto the engine mount. ❑ Remove the engine and drill 5/64" diameter pilot holes through the engine mount, at the marks you drew. ✦ IMPORTANT✦ ✦ Be careful that you drill the holes straight down and not at an angle. ❑ Carefully enlarge the 5/64" diameter pilot holes, using a 1/8" diameter drill bit. ❑ Install the engine using four M3 x 30mm socket-cap screws, eight M3 flat washers and four M3 lock nuts.
❑ Carefully bend the longer of the two aluminum tubes up at a 45º angle, being careful not to "kink" the tubing as you bend it. ✦ IMPORTANT✦ ✦ When the stopper assembly is installed in the fuel tank, the top of the vent tube (the tube you just bent) should rest just inside the bubble in the top of the tank. ❑ Secure one end of the silicon fuel tubing onto the end of the fuel pick-up "clunk.
❑ Slide the fuel tank into the fuel tank compartment, making sure that the bubble in the top of the fuel tank is toward the top of the fuselage, then install the silicon fuel tubing to the aluminum tubes at the front of the tank. PRO TIP Mark the ends of the silicon tubing "vent" and "pick-up" so you don't confuse them when it comes time to connect them to the engine later on.
STEP 2: INSTALLING THE THROTTLE PUSHROD WIRE & ADJUSTABLE CONNECTOR ❑ Remove the throttle arm from your engine and install the Z-Bend in the pushrod wire into the outermost hole in the throttle arm. ☞ You may need to enlarge the hole in your engine's throttle arm, using a 5/64" diameter drill bit, to accommodate the wire. ❑ Slide the plain end of the throttle pushrod wire into the nylon tube in the firewall, then reinstall the throttle arm onto your engine.
❑ Use wire cutters to cut away and remove the excess pushrod wire. ❑ Install and tighten the servo horn retaining screw to hold the servo horn securely to the servo. ❑ Operate the throttle several times to ensure that the pushrod wire does not bind.
❑ Install the 90º bend in the 8-1/2" long threaded rudder pushrod wire into the hole that is 7/16" out from the center of the servo arm, using the nylon snap keeper provided. When installing the snap keeper, make sure it "snaps" firmly into place over the pushrod wire. ☞ The pushrod wire should be orientated on the bottom of the servo arm, as shown. ❑ Thread the nylon clevis onto the rudder pushrod wire.
❑ Remove the masking tape from the rudder and double-check that the servo arm, the rudder and the nose wheel are still centered. If the rudder and/or nose wheel are not centered, adjust the nylon clevis and/or steering pushrod wire until they are. Move the rudder right and left several times to ensure that the linkage assemblies do not bind. Double-check that the nose wheel moves in the same direction as the rudder, too.
✦ IMPORTANT✦ ✦ Before installing the elevator pushrod assembly, it's very important to apply a couple of drops of thin C/A to the machine screws in the wheel collars that secure the two elevator pushrod wires together. This will prevent the screws from loosening during flight. Do not omit this procedure or failure of the elevator control system could result! It's important that you install the wheel collars in the location shown on the full-size drawing.
❑ Carefully snap the clevises into the nylon adjustable elevator control horns. ☞ You may need to adjust the nylon clevises so that the elevator halves stay centered. ❑ Remove the masking tape from the elevator halves and double-check that the servo arm and the elevator halves are still centered. If the elevator halves are not centered, adjust the clevises until they are. Move the elevator halves up and down several times to ensure that the linkage assembly does not bind.
❑ Center the servo tray over the servo cutout in the top of the wing, and while holding the servo tray in place, trace around it using a pencil. ❑ Remove the servo tray and use a modeling knife to cut away and remove the covering material from within the outline you drew. ❑ Glue the servo tray to the wing, using a generous amount of 5 minute epoxy. Remove any excess epoxy, using a paper towel and rubbing alcohol, and allow the epoxy to set up before proceeding.
❑ Install the servo horn onto your servo, making sure that it's centered, as shown. ❑ Install and tighten the servo horn retaining screw to secure the servo horn to the servo. ❑ Use a couple of pieces of masking tape, taped between the ailerons and the wing, to hold the ailerons centered. ❑ Carefully thread one nylon adjustable control horn (large thread) onto each threaded aileron torque rod wire.
✦ IMPORTANT✦ ✦ Before cutting out the cowling to fit over your engine, notice that the cowling has a top and a bottom. The bottom of the cowling is straight and the top of the cowling is angled down to match the angle of the top of the fuselage. ❑ When installed, the cowling will fit around the narrow plywood cowling mounting ring and butt up against the front of the fuselage.
❑ Install your muffler, high speed needle valve, propeller and spinner. To finish off the assembly, cut to length and install the fuel pick-up and pressure lines from the fuel tank to your engine's carburetor and muffler.
STEP 2: INSTALLING THE FUEL TANK HATCH COVER ASSEMBLY ❑ Using a pair of scissors, carefully cut the excess canopy material flush with the fuel tank hatch cover. ❑ Place the fuel tank hatch cover assembly back onto the fuselage and push the mounting tab down firmly into the notch. ❑ Using a drill with a 1/16" diameter drill bit, drill a hole into the mounting tab and through the fuselage. ❑ Carefully secure the fuel tank hatch cover assembly to the fuselage, using one M2 x 10mm flange-head wood screw.
❑ Mount the switch to the fuselage side (opposite the muffler) and connect the battery lead to the switch, and the switch and servo leads to the receiver. STEP 5: APPLYING THE DECALS ❑ Using a clean cloth, wipe the airframe down completely to remove any dust, debris and oil. We suggest using rubbing alcohol to wipe the airframe down in the areas where the decals will be applied. ❑ Cut out each of the decals and apply them, using the box cover photos for reference.
SECTION 20: CONTROL THROWS We recommend setting up the F-20 Tigershark 40 ARF using the control throws listed below. These control throws are suggested for initial test-flying because they will allow the airplane to fly smoother and make it easier to control. TEST-FLYING Ailerons: 3/16" Up 3/16" Down Elevator: 3/16" Up 3/16" Down Rudder: 1" Right 1" Left ✦ IMPORTANT✦ ✦ The control throws are measured from the widest point of the control surfaces.
PREFLIGHT CHECK & SAFETY, CONTINUED.... ● Double-check the balance of the airplane. Do this with the fuel tank EMPTY. ● Check the control surfaces. They should all move in the correct direction and not bind. ● Make sure that you've installed 1/4" long pieces of clear tubing over the clevises to prevent them from opening during flight. If your radio transmitter is equipped with dual rate switches, double-check that they are on the low-rate setting for your first few flights.
Full-Size Elevator Pushrod Assembly Template
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