THUNDER TIGER 5546 User manual
Clear a place on your workbench or table, and let's begin.
CA Instant Glue
Needle Nose
Pliers
Phillips
Screwdriver, Med Hobby Knife Scissors Drill Bit
1/16" , 1.6mm
5/64”, 2mm
1/8”, 3mm
5/32”, 4mm
Tools Required for Assembly
Sandpaper (#400 grit) Rubbing Alcohol
● Read all directions thoroughly before assembly.
● Check the parts against the parts drawing on page 3-4.
● When mixing epoxy, apply equal volume from two bottles.
● When tighten screws, be sure not to overtighten, as the metal thread will strip out or damage the fiberglass,
plywood, plastic or Aluminum.
02
3
Keel and Rudder Tube Assembly
Sequence of the step
22
21
17
16
Refer to the parts listing and locate the needed parts.
The section will be assembled in the step.
Bowline Knot
Figure Eight Knot Reef Knot
Before Assembly
Some Basic Knots
In each step, the needed parts are shown the number right below. Locate all parts for the step.
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37
43
38
35
9
3x5mm
Screw (1)
10
M4 Locknut (3)
11
M3 Locknut (4)
12
M2 Nut (9)
13
Ball (2)
14
Ball End (2)
39
41
40
03
15 16
Winch Line Guide (2) End Cup A
(1) Rudder Tube
(1)
17
Winch Line Guide
B
(2)
18
Wheel Collar (1)
19
21
End Cup B (3)
Foam Tube (1)
Clevis (1)
23
26
Rudder Pushrod (1)
30
Black String (1)
PE String (1) Wire (1) Tie Rod (1)
White String (1)
Winch Servo Cover (1)
31 32 33 34
Swivel (8)
22
Keel Tube (1)
27 28 29
Silicone Tube (1)
25
Standoff (2)
20 24
Steering Arm (1)
O-Ring (3) Rudder (1)
Keel (1) Mount (1)
8
3x8 mm
Sink Screw (4)
2
3x25 mm
Wood Screw (2)
1
4x32 mm
Screw (1)
7
2x12 mm
Screw (9)
5
2x8 mm
Wood Screw (20)
95
2x5 mm
Wood Screw (6)
3
3x15 mm
Wood Screw (4)
4
3x10 mm
Wood Screw (9)
Ballast (1)
Hull (1)
Rudder Well Cover (1)
SCALE
1:1
6
2x14mm
Pin (1)
Bowsprit(1)
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53
52
56
66
68
67
69
65
04
36
Servo Tray (1)
93
Decal A (1)
94
Decal B (1)
49
Head Crane (1)
47
Mast B (1)
Jib Sail (1) Main Sail (1)
51
Jib Boom (1)
50
Main Boom (1)
42
Hatch Cover (1)
45
Hatch Mount (1)
59
Al. Stand A (4)
57
Display Stand (2)
54
PVC Strip (3/L)
55
PVC Strip (2/S)
46
Mast A (1)
62
60
61
63
64
48
Mast Joiner (1)
70 71 72 73
74
7877
76
75
83
79
84
85
86
87
82
81
80
88
90
92
91
89
58
Al. Stand B (2)
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JJ6089
JJ6090
05
58
3
59
28
57
Display Stand Assembly
1. Locate the display stand parts ,
then assemble the stand as
shown at right. Use 3x15mm
wood screw to secure the
Hull Support and Al. Stand
B . You may apply a thin
bead of 5-min. epoxy at the joint
before you insert the Al. Stand B.
2. Next Insert the other four Legs
and install the Feet . It is
not necessary to apply any
epoxy for these four legs and
feet.
3. Locate the black Foam Tube
then use scissors to cut the
foam tube so it can be installed
on the hull support as shown.
This will protect the hull bottom
from scratches during
construction and storage.
4. Now you can place the Hull
on the display stand during
construction.
3
3
28
28
57
57
58
58
56
59
59
41
41
56
56
1
41
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8
92
40
10
38
35
Keel Assembly
2. Thread the O-ring onto the
keel shaft.
3. Apply a generous amount of
epoxy to the slot of Ballast Bulb
and insert the keel, securing
with the M4 Locknut by using
the furnished small 4-way
wrench. Wipe out the excess
epoxy. Excess epoxy that
over-flows the ballast bulb can
be smoothed out with a wet
finger, or removed using rubbing
alcohol. This must be done
before the epoxy hardens.
4. Secure the Stabilizer with the
two 3x8mm Sink Head Screws .
10
10
35
35
38 40
40
92
92
8
8
2
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16
21
17
22
21
21
21
22
16
Keel and Rudder Tube
Assembly
1. Insert the Keel Tube from hull
top and reach the hull bottom then
epoxy the two End Caps in
place. There are three big end
caps and one small end cap.
The small one for the bottom hull.
Note: end caps are working as
waterproof and epoxy will help to
fill the gap between cap and
tube. Keel Tube might need to
trim the length , to keep it level
with the deck. However, do not
leave any excess epoxy on the
inside the tube as it will be difficult
to insert the keel shaft if there is
any hardened epoxy inside.
Note: You may need to sand
contact area A of the hull if tube
is higher than the deck.
2. Using the same way to install
Rudder Tube and the other
two end caps in place then allow
the epoxy to cure.
22
22
21
21
17
17
16
16
3
A
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9
18
18
15
15
37
18
15
10
9
9
10
10
26
26
37
19
19
24
24
4
37
26
9
19
24
1. Drill 4mm hole at the dot then
install the Winch Line Guide A
from the inside of the hull then
secure Winch Line Guide A and B
together on the deck. Do the
same procedure for the other winch
line guide assembly.
2. Trial fit the keel in place,trim the
contact area if necessary. Make
sure the keel fit into the hull
properly. Secure the keel shaft with
M4 Locknut by using the
furnished 4 way wrench. The keel
can make it inconvenient when
moving the hull around during
assembly.
3. Please use care when placing
the hull on stand as the stabilizer
will contact the Al. Stand B, it will
need slightly to rotate the hull and
let stabilizer go through the display
stand.
4. Install Rudder in place by
securing the Steering Arm and
Collar with 3x5mm Screw .
In this step you will need to connect
the Pushrod by threading the
Z-bend end to steering arm first
then thread the other end to the hull
so you can secure the arm with
collar inside to the rudder shaft as
illustration. Note: the pushrod and
rudder should perpendicular to the
steering arm.
Keel and Rudder Assembly
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5
America’s Cup Racing YachtAmerica’s Cup Racing Yacht
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Hatch Cover Assembly Ⅱ
1. Install the Silicone Tube
underneath the hatch cover as
illustration. Start from steering
wheel end then push in the
silicone tube in place. Try to
smoothen the tube as you can.
Hint: Avoid of pulling or
squeezing too much of the
silicon tube. Also do not cut
away silicone tube.
2. Install Steering Wheel
three parts together by using
CA instant glue. Set it aside
and wait final assembly.
3. Glue Winch , Steering
Wheel Stand and Main
Sheet Winch Stand in place.
4. Secure the wheel stand with
3x10mm Wood Screw , next
secure the Winch on the
Main Sheet Winch Stand.
5. Secure the steering wheel
assembly on stand with 2x8mm
Wood Screw .
6. Install the Winch Handle in
place, adjust the handle evenly
then apply tiny CA at the joint.
7. After you done all adjustment
and Ringging, attach the hatch
cover assembly in place.
66 67 68
66
66
25
25
25
4
4
5
5
5
67
67
68 68
81
81
81
84
84
77
77
85
85
86
86
87 87
88
88
84 85
86 87
4
77
88
5
Table of contents
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