Aircraft Modelers Research Giant Stick 85 User Manual

Aircraft Modelers Research-Payload Master 100-132’’ wing span---96’’ fuselage---3 168 Sq. In.80cc/120cc enginewww.amr-rc.comMade in CanadaMarch 24-201

100C.G:DEFLECTIONS:-AILERONS-ELEVATORS-RUDDER25-) Secure the struts with one 6-32 x 1 ½’’ S. H. cap screw and nylon nut. Finished tip. Now, verify tha

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Payload Master 100-Fuselage Assembly-

191-) Trial fit both FB1 and FB2. Set the parts over a strip of wax paper. 2-) Using “Medium Grade” C.A, wick the dove joint. Let cure fully.3-) Repea

2-Warranty-Aircraft Modelers Research Incorporated guarantees this kit to be free from defect in both material and workmanship at the date of purchase

205-) Locate both FS1A doublers (Right/Left) See next step.6-) Set a strip of wax paper on your table. Apply some glue ONLY over FS1A (Right) 7-) Remo

219-) Now, prepare the Left doubler as you did the Right one.10-) Bond the ¼’’ ply doubler FBD over the fuse floor using wood glue. Use the front and

2213-) Locate both F18 ply parts (5-ply type) 14-) Laminate these parts using structural epoxy.15-) Locate both F2 and F2A parts. 16-) Bond F2A over F

2317-) Locate parts F23, F24 and four F27’s. 18-) Insert one F27 into F23. Important: Notice that the small holes in the F27 must be near F23. Do not

2421-) Glue this assembly to F15 using structural epoxy.22-) Remove the ¼’’ ply part F8C from F8. 23-) Locate the 1/8’’ ply part F8B. You will see fou

2525-) Trial fit this assembly into the ¼’’ ply part F8. Sand/shave if required for proper fit.26-) Bond F17 to the rear end section of the fuse botto

2628-) Trial fit F13 over F15 as shown. 29-) Carefully set F13 so that the tabs on F15 are visible. See next picture. 30-) There will be a small diffe

2732-) Insert F2 (F2A facing backwards) into the fuse bottom and insert F10 into F1 and F2. Wood glue can be used for this. 33-) Use multiple clamps a

2836-) Trial fit F15 as shown. Verify that F15 fits properly over and into the formers F2, F3 and F4. 37-) Trial fit the laminated part F18 against F2

2940-) Bond on each sides of the floor a ¼’’ x ¼’’ balsa stick, from the fuse bottom doubler up to F17 tail wheel mounting plate.41-) Set the fuse ove

3IntroductionThank you for purchasing AMR product. AMR (Aircraft Modelers Research) prides itself on bringing you the finest aircraft model kits due t

30*Use multiple clamps as required to keep all of the parts together and let the glue dry overnight* 44-) Insert and glue one part F14 between the fu

3146-) Prepare the fin alignment jig with one “Jig-1”, one “Jig-2” and two “Jig-3” parts. 47-) Assemble the jig as shown. Use thick CA for assembly an

3250-) Bond two F28 triangular pieces. The, bond F21 over them as shown. This will serve as an air exit hole for engine cooling.51-) Bond in position

3354-) Clamp the 3/8’’ balsa sticks as shown. 55-) Trial fit F19 and F19A. You will need to bond some 3/8’’ balsa strips to F5 in order for these part

34Payload Master 100-Wing Assembly-

35Wing jig assembly. This jig is reversible for both Right and Left wing panels. The construction sequences will show the Right wing panel being assem

362-) Using one 3/8’’ x ¾’’ hardwood (spar) bond two W26 on each side of it. Align the parts so they match together. 3-) Tack-glue two laser cut dihed

376-) Position the rib assembly over the spar and set W1 against the jig part WJ3 and both dihedral gauges. 7-) Use the supplied ¼’’ ply rib gauge to

3810-) Slide over them a 3/8’’ x ¾’’ hardwood spar encapsulated with parts W26, same as the bottom spar. Splices in both spars will be required betwee

3914-) Make two hardwood doublers using spar material and bond over the top spar scarf joint.15-) Also make one for the bottom spar scarf joint. Web t

4Before you begin, important notes from A.M.R1-) This model airplane is not a toy. It must be built with outmost care. It is imperative that you follo

4018-) Skin the leading edge with 3/32’’ x 3’’ x 66’’ balsa sheets. A splice is required to make the skin 66’’ long.19-) Skin the rear trailing edge s

4122-) Bond between W15/W16 rib tips a 3/8’’balsa filler piece to mate both top and bottom tip skins. Sand the filler to the contour of the ribs.23-)

4226-) Make a skin 9 ¼’’ x 14’’ and skin the bottom centre section only. Slide a 48’’ cardboard servo lead tube from W1 up to W11. NOTE: Slide the 1 ½

4328-) Locate four W21A’s. See next picture. 29-) Glue four of them over parts W21, centering them over the wing screw hole on the previous picture.30

4432-) Insert plates W33/W34 (Right) between ribs W5/W6 and W11/W12.33-) Reinforce the plates by bonding two strips of left over spar materials on eac

4538-) Carefully drill through the 3/32’’ skin using the hole in W21 as reference. 39-) Using automotive wax, apply a coat of wax to the aluminum tube

4640-) Skin the top centre section of the wing panels, same as the bottom section. Also bond a strip of 3/8’’ x 3/8’’ balsa (trailing edge) between ri

4744-) Cut a 5/8’’ x 1 ½’’ dowel and also drill a ¼’’ hole into it. Bond this one in the W21’s balsa fillers. 5/8’’ dowel45-) Bond two 3/8’’ x 1 ½’’ d

4848-) Bond a 3/8’’ x 3/8’’ balsa trailing edge piece between ribs W15/W16.-Completed wing tip panel section-WING MOUNTING: Trial fit and centre the w

49Payload Master 100-Flaps & ailerons assembly-

553/32" x 4" x 48"Balsa sheets15/8" x 6"Horn dowel 1½’’ x ½’’ x 6"Hardwood13/32 x 4" x 48"Balsa sheet13/8"

501-) Begin with the Right aileron. Locate the laser-cut ¼’’ balsa parts Aileron-1 and Aileron-2. 2-) Set them against a 4-foot level to keep them str

515-) Insert two A4 ribs into the six small square cavities. These are hinge supports. 6-) In the larger square cavity, insert one A3 rib. Do not glu

529-) Cut a 3/32’’ x 1 3/8’’ x 32’’ strip of balsa and pin it to the ribs as shown. Use a level with weights over it to keep the aileron strait. 10-)

5313-) Cut a strip of ¼’’ x 1 5/8’’ x 32’’ balsa and glue/pin it to the front of the aileron. Use a level with weights over it to keep the aileron str

5417-) Begin with the Right flap. Repeat the same process as for the aileron.18-) Insert and bond the F1 ribs.19-) Insert the F4 ribs. 20-) Insert on

5521-) Bond a strip of 3/32’’ x 1 3/8’’ x 22’’ to the trailing edge. Apply weigh to the flap to keep it strait. 22-) Bevel sand the top skin and botto

56Payload Master 100-Aileron/flap hinge installation-Note from AMR:The hinging techniques described in the following pages will demonstrate a fool pro

571-) Begin with the Right flap. Position the flap and leave a 1/8’’ gap between rib W3. Lay a strip of masking tape over the wing skin and the flap s

585-) Using a small Moto-Tool grinding stone, slightly enlarge the pilot holes in both wing/flap.6-) Using a 1/8’’ drill bit, drill thought the pilot

599-) Insert five Robart hinges into the wing and slip the flap in place. 10-) You may need to enlarge the holes with the grinding stone for a perfect

6-Payload Master 100/Hardware part list-1 setAirwild/cable fittings203/16"Robart Hinges/Ailerons16 foot longKevlar string163/16"Robart Hinge

6011-) Hinging of the Right aileron. Repeat the same masking tape process as for the flap. NOTE: The wing bottom should be facing your work table.13-)

6115-) Using a larger Moto-Tool grinding stone, enlarge the holes in both wing/flap.16-) Using a 3/16’’ drill bit, drill through the holes at least 1

62Payload Master 100-Fin & Rudder Assembly-

631-) Bond F2 (dorsal fin) to F1 and lay F1/F2 fin parts and F3 rudder part over wax paper. The idea is to bond specific ¼’’laser-cut balsa parts on b

642-) Following the part numbers, bond on both sides of the cores the ¼’’ laser-cut balsa parts. Thick C.A is recommended. Some 3/8’’ x 3/8’’ balsa st

653-) Trial fit the fin into both F14 and F19A. 4-) Verify that the notches in F19A fit with the tabs in F2 (dorsal fin)5-) Locate the fin post made

667-) Trial fit the fin post. You will have to notch the bottom of the balsa block to accommodate the F17 tail wheel plate. 8-) The fin post must fit

6711-) Trace a line on both sides of the rudder, 3/16’’ behind the hinge line. 12-) Bevel sand/shave in order to obtain a 30-degree deflection on both

68Payload Master 100-Stabs & elevators assembly-Note from AMR:The stabs and elevators are built into two separate panels using a reversible jig. I

691-) Begin with the Right stab. Locate both laser-cut plywood parts “Front Jig”, “Rear Jig” and both “Side Jig”. NOTE: The writing “Right Panel” on b

705-) Insert two ¼’’ plywood ribs R1/R2 and the remaining ¼’’ balsa ribs R3/R7. See next picture.6-) The stab is built upside down. Notice the orienta

719-) Set your level and some weight over the ribs. You will need to shim the ribs R6/R7 with some 3/32’’ balsa under the level. Bond both spars to th

7213-) Cut a 3/32’’ skin to fit between the rear dotted cut-line and the end of the ribs. 14-) Apply glue to all the ribs except the tape covered R1 r

7317-) Bond the rear spar in place. Verify that it is properly set in the ribs. 18-) Repeat for the front spar. Verify that it is properly set in the

7421-) Cut a 3/32’’ skin from the rear dotted cut-line up to the rib tips. 22-) Apply glue to the ribs and bond the skin in place. 23-) Using a knife,

7525-) Cut a ¼’’ x 1 1/8’’ x 24’’ balsa and glue it so that the balsa extends past the ribs as shown. Important.26-) Prepare a 2’’ wide 3/32’’ balsa s

7629-) Again, verify that the dotted cut-lines faces in this direction, as shown in the picture. Important. Now, repeat the same construction method a

7733-) From some 1/8’’ left-over plywood, cut four small squares and bond them to the outside of ribs R2 in both stabs. These are tube stoppers. Front

7837-) Using the remaining phenolics, insert them into the front and rear fuse holes. Mark and cut them. Same process as for the stab panels. 38-) Cut

7941-) Set your fuselage on your work table at 0-0 degrees and secure it in place using weights inside of the fuselage. 42-) Install one incidence met

8045-) Repeat the same procedure for the other stab panel. 46-) Tack-glue the phenolics using Thick C.A. NOTE: Do not allow the C.A to enter in contac

8149-) Using a disposable brush and structural epoxy mixed with micro-balloons, create glue fillets against all the phenolics and surrounding parts in

8253-) Skin the remaining rib leading edges and sand flush with the ribs. 54-) Cut twelve pieces of ½’’ x ½’’ x 1’’ from the supplied 12’’ balsa stic

8357-) Bond stab tip rib R8 on both stab and elevators. 58-) Place the Left elevator over the Left stab. Transfer the hinge markings from the stab tra

8461-) Trim the 3/8’’ hinge plate flush with the elevator tips, not the root section. 62-) Position and tape the elevators to their stabs. Using the s

8565-) Once proper fit of R1 tip ribs, bond in place. 66-) On the bottom of each elevators, near rib R2, press on the balsa and open up a 5/8’’hole. 6

8669-) Bond the dowels using wood glue. Those are the elevator horn mounts.70-) Bond a strip of 3/8’’ x 3/8’’ x 20’’ over the trailing edge of the ele

8773-) Drill using a 1/8’’ drill bit. 74-) Enlarge the holes using a larger grinding stone. 75-) Drill now using a 3/166 drill bit. 76-) Install the

8877-) Cut two ½’’ x ½’’ x 1 ¼’’ hardwood pieces and drill a small 1/8’’ hole in the middle of them. Bond these blocks on R5 rib exterior, in front of

89Payload Master 100-Tail group flying wire assembly-

901-) Cut a 3/8’’ dowel piece and drill in the middle. Bond inside the fin. Prepare two Sullivan Steel Straps, one 4-40 x 1’’ S.H cap screws and one 4

915-) Secure the straps over the ½’’ square hardwood block in each stabs with a 4-40 x 1 ½’’ S. H. cap screws and nylon nut. Do not tighten yet.6-) Sl

929-) Using the supplied steel sleeves, loop the Kevlar string thought it and the Sullivan tabs on both side of the fin. Do not crimp yet.10-) Verify

93Payload Master 100-Landing gear, windowand wing struts installation-

941-) Install the main gear legs using eight 10-32 x 1 ½’’ S.H. cap screws and T-nuts set inside the fuse gear plate. 2-) 10-32 T-nuts shown inserted

955-) Around all window openings, there is a small “frame”. 6-) Trial fit the plastic windows but leave the protective film on both sides of the plast

969-) Struts: Both Right and Left strut pictures will be shown in the next steps. Locate both angled 3/16’’ thick aluminum fuselage brackets.10-) Inst

9713-) Locate two 3/32’’ aluminum wing panel brackets as shown and two 6-32 x 1 ½’’ S. H. cap screws and nylon nuts. 14-) Loosely secure the wing pane

9817-) Place the struts on its width and cut a 1’’ deep slot using a band saw. 18-) Insert the 1/8’’ aluminum strut bracket into the strut, centre it

9921-) Make a hardwood block 5/8’’ x 7/8’’ x 1’’ wide. Drill a 6-32 hole thought the 1’’ thickness. Loosely set the block between the wing brackets us