Stevens Aero Model SCRAM! User manual

SCRAM!

1/2A Electric Control Line Combat by Stevens AeroModel

Length 12 inches | Span 18 inches | Wing Area 100 inches2| Flying Weight 4 - 4.5 oz.

Version 12/24/2009

Product Support

WARNING! DANGER!

DO NOT FLY MODELS NEAR ELECTRIC POWER LINES. INSTANT DEATH CAN RESULT FROM

CONTACT WITH, OR FLYING TOO CLOSE TO, ELECTRIC POWER LINES.

WARRANTY

Stevens AeroModel guarantees this kit to be free from defects in both material and workmanship at the

date of purchase. This warranty does not cover any component parts damaged by use or modification.

In no case shall Stevens AeroModel’s liability exceed the original cost of the purchased kit. Further,

Stevens AeroModel reserves the right to change or modify this warranty without notice.

LIABILITY RELEASE

In that Stevens AeroModel has no control over the final assembly or material used for final assembly,

no liability shall be assumed nor accepted for any damage resulting from the use by the user of the final

user-assembled product. By the act of using the user-assembled product, the user accepts all resulting

liability.

If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is

advised to return this kit immediately in new and unused condition to the place of purchase.

THIS PRODUCT IS NOT INTENDED FOR CHILDREN 12 YEARS OF AGE OR YOUNGER

WARNING: This product may contain chemicals known to the State of California to cause cancer and

or birth defects or other reproductive harm.

PRODUCT SUPPORT

This product has been engineered to function properly and perform as advertised with the suggested

power system and supporting electronics as outlined within this product manual. Product support

cannot be provided nor can Stevens AeroModel assist in determining the suitability or use of

electronics, hardware, or power systems not explicitly recommended by Stevens AeroModel.

For product assembly support, replacement parts, hardware, and electronics to complete this model

please contact Stevens AeroModel on-line at www.stevensaero.com.

Project Checklist

Kit Contents

Laser cut wood (8 Sheets - See inventory on following pages)

Illustrated instruction manual

1 - 1/32 in. x 12 in. music wire (taped to back of wood brick)

1 - 3/16 in. square x 18 in. length hardwood stock (Leading Edge)

1 - 3/32 in. x 3/16 in. x 12-3/4 in. Basswood Stock

Large Hardware Bag (4 x 6 in.)

1 - 1/2 in. x 5 in. strip 2-sided velcro (Battery Safety Strap)

1 - Nylon Bell Crank

1 - 2 in. x 1/32 I.D. Nylon Tube (Lead-out Wire Guides)

1 - 36 in. length 0.012 Stainless Wire

1 - “W8” Laser Cut Basswood Part (3/32 in. x 3/16 in. x 3-1/4 in.)

Small Hardware Bag (2 x 3 in.)

1 - US Nickle (Cheaper than Lead thanks to the Fed!)

1 - 0.060 in. OD x 2 in. Length Carbon Rod

1 - 4-40 Blind Nut

1 - 4-40 x 3/8 in. Pan Head Machine Screw

1 - Du-Bro RC 4-40 Hex Nut [DUB561]

1 - Du-Bro RC Micro Razor Control Horn [DUB936]

1 - Du-Bro RC Micro EZ-Link [DUB849]

1 - Du-Bro RC Mini E/Z Connector [DUB845]

1 - 3/32 in. OD x 1-5/16 in. Length Aluminum Tube

2 - Du-Bro RC #4 Flat Washers [DUB323]

4 - 1/16 in. OD x 1/4 in. Length Aluminum Crimp Tube

Required Electronics & Equipment (Available at StevensAero.com)

1 - StevensAero/Suppo Park 300 Brushless Outrunner Motor [SUPA2204-19]

1 - StevensAero/Suppo 10A Brushless ESC [SUP10AESC]

1 - E-flite Control Line Motor Timer [EFLA172]

1 - ThunderPower RC Pro-Lite V2 350mAh 11.1V LiPo Battery [THP3503SJPL2]

1 - GWS 6x3 HD Propellor [GW/EP6030]

1 - SIG 1/2A Control Handle, inc. Dacron Line and Connectors [SIGSH544]

Required Building Supplies and Tools

1/2 oz. Medium CA Glue [PAAPT09]

1/2 oz. Thin CA Glue [PAAPT03]

1/2 oz. Thick CA Glue [PAAPT20]

CA glue accelerator [PAAPT15]

Balsa filler [HCAR3401]

Hobby Knife with ample supply of #11 blades

Small Phillips Screwdriver

Small Hammer

Sanding block with 400 and 600 grit paper

Heat Gun and Covering Iron

Small Needle Nose Pliers

Small Round Nose Jewelers Pliers

X-ACTO Pin Vise Set [XAC7155]

ZONA 4 in 1 Saw Set [ZON35251]

Scissors

Wire Cutters [HDCUT093]

Z-71 Thread Locker [PAAPT71]

1 in. x 4 in. length sticky back velcro

1 Roll StevensAero AeroLITE

Suggested Building Supplies

CA glue de-bonder [PAAPT16]

Long sanding bar

Razor Plane

Low Tack Painters Masking Tape

Design Master Aerosol Paint

General Assembly Instructions

Thank you, for purchasing this Stevens AeroModel SCRAM!, A design inspired by the joy of flying. This

model has been developed and manufactured using state of the art CAD/CAM systems and features a

unique interlocking construction process that, when compared to traditional methods found in other model

aircraft kits, save countless hours of measuring, cutting, sanding, and fitting. We are certain that you’ll

find our kit to offer a truly exceptional build experience. As this kit is recommended for the novice model

builder and “pilot”; we invite absolute beginners to correspond with us, or to seek the help of another

seasoned builder. At any time should one run across a term or technique that is foreign please don’t

hesitate to contact our staff with your questions.

READ THIS

Please READ and RE-READ these instructions along with any other included documentation prior to

starting your build and or contacting our staff for builder support.

Pre-sanding

Do not skip this step. Prior to removing any parts from the laser cut sheet wood use a sanding block

loaded with 250-400 grit paper and lightly sand the back side of each sheet of wood. This step removes

any residue produced as a result of the laser cutting process and, as we have found that most stock wood

sizes run several thousandths of an inch over sized, slightly reduces the thickness of each sheet.

Leave your pre-sanded parts in the sheet until required in the assembly process.

Protecting your worktable

Use the poly tube that this kit was shipped in as a non-stick barrier between your worktable and the

product assembly. Promptly clean up any epoxy spills with rubbing alcohol and a disposable towel.

Bonding the assembly

As this product tabs, notches, and otherwise interlocks like a 3D puzzle we suggest that when fitting parts

you dry fit (use no glue) the parts together first. It’s advised to work 1-2 steps ahead in the instructions

using this dry-fit technique which allows ample opportunity to inspect the fit and location of assembled

components and realizes a benefit as each successive part contributes to pulling the entire assembly

square. Once you arrive at the end of a major assembly step(s) square your work on top of a flat building

table and revisit the dry fit joints with glue. Using the dry-fit process you’ll be able to recover from a minor

build mistake and will ultimately end up with a more square and true assembly.

Unless otherwise noted in the instructions, always use medium CA glue for bonding parts.

Never force the ﬁt!

Remember this is a precision cut kit our machines cut to within 1 thousandth of an inch in accuracy. Yet

the wood stock supplied by the mill may vary in thickness by up to 20 thousandths. This variance in the

wood stock can cause some tabs/notches to fit very tight. Hey, dad always said it was easier to take

away material than add it back. With this in mind, should you find a joint or two to fit rather snug consider

lightly sanding a tight fitting tab rather than crushing and forcing your parts together. You’ll break fewer

parts in assembly and will end up with a more square and true assembly.

Wing Construction

Locate the 4/40 blind nut within the hole in

W6L. Ensure that etching on W6L faces up.

With a hammer, seat blind nut firmly in W6L.

Secure with medium CA at edge of nut flange.

Bond together both ribs R1 with medium CA.

Align carefully, match at notches and profile.

Fit and bond trailing edge parts W3a and

W3b.

Dry fit R1 assembly to trailing edge. DO NOT

BOND AT THIS TIME.

Fit gussets W4 to trailing edge and R1

assembly. Align and bond.

Wing Construction Cont.

Slide dovetailed end of W6L through the left

side of the slot in R1 assembly. Ensure that

etching on W6L faces up, and blind nut is on

top as shown. DO NOT BOND.

Note that dovetail will protrude through R1.

Dry fit left R2 to trailing edge and W6L. DO

NOT BOND.

Fit W6R to W6L. Fit left R2 to W6R and

trailing edge. Be sure entire assembly is flat

and square. Tack glue all joints with thin CA.

Note that W6R will “dovetail” into W6L as

illustrated below.

Fit ribs R3 and R4 to trailing edge. Tack with

thin CA.

Wing Construction Cont.

Dry fit upper laser cut balsa front spar part

“W1” to upper notches in ribs R1-R4.

Dry fit 3/32 in. x 3/16 in. basswood stock to

notches below W1 front spar spanning ribs

R1-R4 to form lower front spar.

Insert rear spars W5 through all ribs. Ensure

that structure is flat and square, and bond all

joints with CA.

Mark center of 1/4 in. square hardwood

leading edge stock. Align mark with center of

wing at R1, then bond leading edge stock

within notch at leading edge of all ribs.

Build left wing tip. Align and bond TL2a,

TL2b, and TL2c atop part TL1 with thick CA.

Align and bond TL3 ton top of TL2 parts with

thick CA. Ensure that lead-out slots are not

blocked with CA.

Wing Construction Cont.

 Dry fit left wing tip assembly to left side of

wing at trailing edge.

 Carefully nest leading edge stock within

slot at front of wing tip.

 With wing tip fit flush to rib R4, leading

edge, and trailing edge, bond with

medium CA.

Build right wing tip. Align and bond parts TR2

atop TR1 and TR3 atop TR2 using thick CA.

Repeat prior steps to bond right wing tip

to right side of wing assembly.

Bond a nickel (5 tip weight) within pocket

created by TR2 at right wing tip. (Inflation...

Prior to going off the gold standard, a nickel

would have purchased this kit. Today, the

nickle is more affordable to use than lead!)

Use a razor saw to trim the excess leading

edge stock at left and right wing tips.

Wing Construction Cont.

Bond with thick CA, R2a cross grain doubler

to outside edge of right rib R2 (this is the rib

adjacent to battery tray W6R).

 The inside surface of W2, leading edge

sheeting, has been laser scored and

center marked as illustrated below. Align

rectangle etched to W2 sheeting with

center rib R1 to center leading edge

sheeting with wing assembly. The closer

spaced score lines on W2 indicate the

side of sheeting that should be installed

closest to the hardwood leading edge

stock.

 Bond W2 leading edge sheeting first, only

to top of the 1/4 in. leading edge stock.

 Starting in the center of the wing,

carefully bend down W2 sheeting to

follow contour of ribs and bond to the

upper spar W1. Work from the center

out, one rib bay at at time, alternating

from right to left side of wing.

 Bend end of W2 down to sit flush with

wing tip and bond. W2 should stop short

of wing tip profile as shown.

 Repeat steps above to install the

lower leading edge sheeting W2.

Fit W4 cap strip to top of rib R1 assembly.

Bond against leading edge sheeting first.

Wing Construction Cont.

Press W4 flat against trailing edge and bond

with CA. Bond the rest of W4 to R1 assembly.

Carefully sand W4 to a smooth taper into the

trailing edge. Tip: apply masking tape to

areas you wish to protect from the sanding

process.

Invert wing and remove stand off tabs. Note

there are two tabs on R1 assembly.

Bond W11 to bottom of rib R1 assembly. W11

should be centered on R1 and fit flush against

leading edge sheeting.

Bond basswood part W8 to bottom of lower

rear spar spanning ribs R2.

Fit and bond ply W7 pushrod exit centered to

R1 ribs as illustrated.

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