Construction Manual Read all Safety notes before proceeding with this Construction Manual. It is recommended that the builder read this Construction Manual in it’s entirety before building any portion of the supplied kit.
A Word About Safety • The Robin is a highly engineered kit that requires the modeller to follow exact instructions to complete the kit properly. Failure to follow the instructions provided may result in loss or damage to the kit or to persons and property. Take your time building this kit. Attention to detail is required in completing each section. • Do not alter/modify this kit beyond its designed specifications. Over stressing the kit in any way (i.e.
Let Us Help You Important: Read During the construction or operation of this model airplane, if at any time you are unclear about any part of the build process or have questions on flight, CALL US FIRST. We cannot stress this enough. Building this kit while unsure of any particular aspects of this kit’s construction or operation may result in unwanted flight behaviour. Read this Construction Manual first before starting. Familiarize yourself with all aspects of the construction; then begin.
Table of Contents A Word About Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III Creating the Horizontal Stab (H.S.)/Elevator 18 If Things Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV Creating the Horizontal Stab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Creating the Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Elevator Horn . . . . . . . .
Forward A few notes from Andy Lennon The Robin is a versatile model airplane, with a wide speed range, that can take off and land in either of two modes: the conventional mode or the STOL mode (short take off and landing) – made possible by several unique features which are described below. It is a “fun” airplane. The wing features large slotted flaps that cover 65% of its trailing edge and when extended 40 degrees, virtually double the lift of that 65% of wing area. The wing’s airfoil is the Eppler E197.
The Wing Wing Construction Glue and clamp together Main Centre Spar layers, to create the laminated Main Centre Spar and Rear Centre Spar. Leave to dry. The three pieces that make up the Main Centre Spar must be glued together very precisely. Each of the 3 pieces have a slight lengthwise curve. Ensure the insides of the curves face each other (this cancels out any over-all curve) and glue together.
Installing Ribs Place Main Spar upside down on its top edge. Along side it, place a 3⁄8" x 3⁄16" stick - wide side down. Dryfit Rib B into the first slot so that it holds the balsa stick against the Main Spar. See Figure 2. Note: In Figure 2, Rib B and the Main Spar are shown upside down, as constructed. Also note that the end of the stick must extend slightly past the end of the Main Spar. This will be trimmed later. Continue to dryfit Ribs C to J.
Glue Rib G1 on the outboard side of Rib G. Fig 4 Dryfit the upper and the lower 1/4" x 1/8" sticks into the slots of every Rib behind the Rear Spar. (See Plan Sheet 2) Slide Rib G1 in Glue two Aileron Cable Anchors into the slots of Rib G1 as shown in Figure 4. Trim flush the sticks that protrude from the inboard upper and lower Main Spar and Rear Spar, as shown in Figure 5. Repeat the “Constructing the Leading Edge Spar” instructions to create the opposite side of the wing.
Locate all eight Flap Support Arms. Glue two Flap Support Arms to either side of Rib C and to either side of Rib E as shown in Figure 8. Before the glue cures, use a 3/32" wire to align the hinge holes as shown in Figure 9. Repeat for the opposite side of the wing. Fig 9 Fig 8 Creating the Slot Lip (TE) Locate the Trailing Edge Stock (3/16" x 3/4"). Cut two pieces, each 22" long. Apply glue to the trailing edge of Rib A to Rib G on both sides of the Wing, and install both pieces of Trailing Edge Stock.
Position each Aileron at the edge of a table and use a sanding block to sand the edge of the Aileron Base Sheet to a fine point. Locate the two Aileron Top Sheets. Dryfit each Top Sheet along the upper tabs of the Aileron Ribs/Horn. Wick thin CA glue into the tabs of each Aileron Rib/Horn. (Note: To avoid a twisted Aileron, hold the assembly down on a flat surface as CA glue is applied.) Once the Top Sheet has cured, sand the trailing edge to almost a fine point.
Dryfit Flap Pivot Ribs into the two remaining slots, then dryfit both Flap assemblies into the trailing edge of the Wing so that the Flap Pivot Ribs drop into the Flap Support Arms, as shown in Figure 11. Using thin CA, glue the back tab of each Flap Pivot Rib and just the rear portion of each Flap Pivot Rib. Be sure no glue contacts the Flap Support Arms. When glue cures, remove both Flap assemblies and complete the gluing of each Flap Pivot Rib.
Test fit the Flap in its position on the Wing. If the hole in the Flap Pivot Rib and the Flap Support Arm do not line up, sand the underside of the trailing edge stock to allow more room for the Flap to enter. (See Figure 13) Sand and profile the Flap Support Arms to match the profile shown on Plan Sheet 2. Locate the 8 Sheeting Supports. (See Plan Sheet 2.) Glue them onto the sides of each Flap Support Arm.
Control Cables The supplied cables should be distributed as follows: Two 36" cable/sleeves are for the Rudder and Elevator. Each 48" cable/sleeve = 1 Aileron and 1 Flap for one side of the Wing. Install an empty 48" Sleeve into the Aileron cable path, and trim. The remainder is for the Flap control. Do not cut both 48" cables the same - the port side of the wing is a longer cable length. You will have to make an opening in the Lower Aileron section of the Wing’s sheeting for the Cable to exit. (See Figure.
Fuselage Locate the following: • Battery Box Walls • Battery Box Floor • Firewalls: F2A and F2B • Formers: F3B to F13 • Fuselage Bolt Plates, three A & two B parts. • Undercarriage Mounts, A and B • Side Support Walls • Main Servo Tray Hardware • Airvent Sidewalls, two A & two B parts. • Fuel Tank Floor • Fuselage Sidewalls • Fuselage Floor • Hatch Bolt Assembly • Wing Saddle Doublers • Two Hatch Hooks • Tail Steering Block Parts 4 Cable with Sleeve, Steering Arm, and 2 Clevises.
Locate the Fuselage Bolt Plates, three A and two B parts. Fig 19 Sandwich one B part between both A parts and test fit this laminated beam into the top slots of F5B before applying glue. Use lots of glue to laminate all three beams altogether and glue them into the slots along the top of F5B as shown in Figure 19. A Glue the long edge of the laminated Beam and the edges of the Battery Box and install F5A on these glued edges. Use large pliers to coax the top of F5A to connect with the Beam properly.
Locate Main Servo Tray. Glue it into the slots midway up F5A, as shown in Figure 22. Apply glue to the exposed edges of the Undercarriage Mount, the Side Support Walls and the Main Servo Tray. Install F4 on these glued edges. Fig 22 Before glue cures, temporarily dryfit the whole assembly into the slots of both Fuselage Sidewalls and Fuselage Floor - ensuring all parts cure in perfect alignment. See Figure 23. Fig 23 Locate the Airvent Sidewalls.
Remove the Fuselage Sidewalls & Floor from the main structure. Locate a 3/8" square stick. Install it vertically down between the edges of F5A and F5B. Trim the lower part of the stick to match the Formers’ diagonally cut bottoms. At the top, you must cut out part of the stick to match the Former shape as well. Repeat for the opposite side. Repeat this process again between F6A and F6B. See Figure 26 which shows only the right side done between the two sets of Formers.
Glue the edges of F7 and install into the Fuselage Sidewalls. The Hatch Bolt Assembly must be pointing forward and be at the top. See Figure 29. Fig 29 If your Fuel Tank Floor has cured into F4, it is time to glue the laminated Firewall to the forward end of the Fuel Tank Floor. Apply glue to the end of the Fuel Tank Floor. (Note: We are NOT gluing the Fuselage Sidewalls to the Firewall until the Firewall has cured to the Fuel Tank Floor.) Now attach the Firewall to the end of the Fuel Tank Floor.
Steering Block Locate F8 and F9. Apply glue to their side edges. Install each between the Fuselage Sidewalls, making sure that the “Star” is on the starboard side. Clamp until glue cures. Refer to diagram on Plan Sheet 1 for the Tail Steering Block and assemble it with wood glue. Be sure to glue the assembly on the back side of F10. When glue is cured, Install F10 into position. See Figure 34. Glue the sides of F11B. The side hole goes on the starboard side. Install and clamp until cured.
Lay your supplied Cable Wire on Plan Sheet 1 and cut the Cable Wire for the Elevator to length. On the Elevator Cable Wire, solder a Solder Link to the rear end, and install it into the Elevator Cable Sleeve. With thin CA, glue in the Fuselage Floor making certain that the hole behind F10 is on the port side. (Do not apply glue to the bottom of F4 and F5A in a way that would seal the lateral lasercut lines in the Fuselage Floor. These pre-cut slits must be kept clear of glue for a later building step.
Sand the protruding Rudder Control Cable Sleeve flush with the Fuselage Sidewall. The Cable will need to be withdrawn from this section of Rudder Sleeve. Remove the remaining tape and set aside Fuselage Sidewalls Parts D. Locate little F11A. Dryfit F11A into the Fuselage Top Sheet slot, above F11B. Glue with thin CA. Except for F12, CA glue the Fuselage Top Sheet to all Formers. Remove only the tape that holds the Fuselage Top Sheet against the Sidewalls.
To make the Tail Gear, bend the supplied 1/8" wire according to the diagrams on Plan Sheet 1. Careful: Don’t bend corners too sharp. The shape on the plans is not critical. The shape shown here is acceptable. Install the Tail Gear through the Fuselage Floor, into Tail Wheel Block, and through the Steering Arm. Be sure the Tail Gear is raked backwards not forward. Set the Tail Gear so that it is parallel to the Steering Arm. Now tighten the Steering Arm screw really tight.
Creating the Horizontal Stab (H.S.)/Elevator H.S. shown upside down Creating the Horizontal Stab Locate the following: • 2 Horizontal Stab Base Sheets • 2 Horizontal Stab Top Sheets • 10 Horizontal Stab Ribs • 2 Horizontal Stab Doublers • Parts A and B of Horizontal Spar Preassemble parts A and B of the H.S. Spar. Build both halves of the Horizontal Stab (H.S.) at the same time. Locate the two H.S. Top Sheets. They are slightly deeper than the H.S. Base Sheets. Fig 43 On each H.S.
Dryfit one H.S. Base Sheet onto the upper tabs of the H.S. Ribs. Use thin CA to glue this Base Sheet in place. Commence the gluing along the H.S. Spar. When the Base Sheet tab opening, sides and Spar edges are glued, pinch together the H.S. Base Sheet and Top Sheet. Use thin CA to glue the forward tips of these two pieces together. Finally, to close the centre of the Horizontal Stab, locate the reserved 11⁄8" x 3" piece of balsa sheeting.
Dryfit the Elevator Spars onto the ends of the Elevator Ribs. Apply thin CA glue to the base of the Elevator Spar, where it contacts the Elevator Base Sheet. Locate the four 3/16" Elevator Doublers. On each inside end of the Elevator, glue on two Doublers with thin CA. The Elevator Doublers will extend beyond the end of the Elevator Top Sheet slightly. Sand Line Sand the trailing edge of the Elevator to a fine point. Install the Elevator Base Sheet.
Elevator Horn Locate the supplied 3⁄32" wire and brass channel stock. Cut the brass channel stock to 11⁄8" long and remove 1⁄2" of one of the brass walls as shown in Figure 48. On that same end (where the wall was cut away), drill a 1/16" hole and drill a 3/32" hole on the other side. Removed wall section Bend the 3/32" wire to the exact width of the distance between the two holes that were drilled into the Elevator. It should resemble Figure 48.
Main Hatch Forward Hatch Structure Locate HS6, HS7, HS8 (x2), HS9, HS10, HS11, HS14 (x2), and HS15 (x2). Dryfit HS11 onto the Pegs behind the Firewall. Note the orientation. Locate HS7 and HS 8 (x2) and refer to the Hatch diagram on Plan Sheet 1. HS7 keys into the lower openings of HS9. Glue the bottom tabs in place. The top leans against HS6, unglued. Glue both HS8 parts to the front of HS6, resting them on the top of HS7. This will lock HS7 in place.
Aft. Hatch Structure Continue to refer to the Hatch diagram on Plan Sheet 1 to build the aft. section. Locate HS1, HS2, HS3, HS4, HS5, HS12 (x2) and HS13 (x2). Wood glue HS1 and HS2 together. Glue both HS12 parts to the sides of the laminated HS1 and HS2. Glue this assembly into HS3. Glue the Hatch Spars (HS4 and HS5) across both HS12 parts. Onto the ends of HS3 and both Hatch Spars, glue the HS13 parts. When the aft.
Trim back the top sheeting as shown and carefully sand to the angle of the formers (black arrows). Locate and glue on one set of Balsa Hatch Doublers, being careful to match the profile of the Hatch (white arrows). Temporarily position the Wing on the Fuselage. Clamp the Wing to the Fuselage when the Wing position is straight. Use a 1⁄4-20 Tap to cut threads into all four holes of the Fuselage Bolt Plates. Add 1⁄4-20 Nylon Bolts as you complete each hole.
With the Balsa Hatch Doublers in place, install the top Corner Strips for the tail. Cut these out of the provided 3⁄16" balsa. Before gluing on the Strips, use a sanding block to sand across the edges of the Fuselage Top Sheet and Sidewalls, creating a good, angled contact for the Corner Strips. See white arrows in Figure 51. As the above edges were sanded, sand the Hatch Top Sheeting and Hatch Sidewalls to create good, angled contacts for the sheeting in the next step.
Completing the Tail Pull the Elevator Cable half-way out of its Sleeve and hook up the Elevator Cable to the Elevator Horn. Be sure to use a keeper. Slide the Horizontal Stab into place temporarily removing F12 in the process. Take great care to make sure the Horizontal Stab is straight and centred. Use CA to lock it in place. Install & glue F12 with CA, and the Fuselage Sidewalls Parts D. Revisit the Horizontal Stab with wood glue around all areas where contact is made with the Fuselage.
Test fit the Vertical Stab. If the Vertical Stab is not perpendicular to the Fuselage top, shave a small amount of balsa off the port Sidewall; see arrow in Figure 54. Glue the Vertical Stab and lower triangle stock in place. Trim the 1⁄4" triangle stock flush with the top of VS4 and the bottom of the Fuselage. Now would be a good time to run your Antenna. Examine the Antenna Path shown on Plan Sheet 1. Fig 54 Sheeting the Vertical Stab Locate the laser cut 1⁄16" balsa sheeting for the Vertical Stab.
Position the remaining port side Rudder sheet. Pinch the trailing edge together while applying CA glue. Be careful not to introduce distortion to the trailing edge. Sand the trailing edge to a point. If there was some distortion in the trailing edge, you now have the opportunity to sand it out. Use a balsa stripper to cut a strip of 3⁄32"x3⁄32" balsa. Allow an inch extra at the lower end for the next step. Glue it to the starboard leading edge of the Rudder.
Locate the 3 blocks of laser-cut 3⁄16" balsa for the top of the Rudder. With CA, glue all 3 pieces together and then to the top of the Rudder. See Plan Sheet 1. Be sure the block is centred on the top of the Rudder. Sand the leading edge of this block to match the round profile seen on Plan Sheet 1. Do not round the top edges just yet. Locate the two triangular blocks of laser-cut balsa for the top of the Vertical Stab. Glue both blocks together, and then to the top of the Vertical Stab.
Building the Nose The Upper Cowl Fig 56 To create the Upper Cowl, locate F1B and all UC1 to UC5 parts. Glue together UC3 and UC4 parts as shown in Figure 56. Glue both assemblies to the front side of UC1 as shown and as seen on Plan Sheet 1. Into UC1, glue both UC2 parts. Glue F1B into the keys of both UC2 and UC4 parts. Glue on UC5, keying it into UC1 and F1B. The Lower Cowl Onto the LC3 and LC1 parts, glue LC2. To create the Lower Cowl, locate F1C and all LC1 to LC4 parts.
Glue both Lower Cowl Arms (LC4) into LC1. The Arms are meant to be loose to allow them to lean in, supporting F1C. Use caution when letting these assemblies cure. Butting them up against each other will ensure a true fit when they cure. Glue F1C onto the Lower Cowl Arms and LC2. While things dry, there are a few things to take care of. Using 1⁄2" triangle stock, cut some supports for the corner behind the Firewall. Sanding will be required to match the 95˚ corner before gluing the supports in place.
Locate the supplied 15mm Snaps. Using epoxy, glue the female end into the Firewall. Be careful not to get epoxy into the spring components. Glue and clamp the Upper Cowl assembly to the Firewall. Make sure it is straight and centred. Note: The top edges will not be flush. Once the Upper Cowl assembly has cured, clamp the Lower Cowl into position. DO NOT GLUE. Locate the two small Cowl Hooks as shown above. Glue these Cowl Hooks to the Upper Cowl assembly ONLY.
Once the Lower Cowl sheeting is sanded, glue F1D onto F1C. The angled sheeting is built up of layers of 1⁄16" balsa. You may use thicker material to achieve the same result, but the first layer must be 1⁄16" balsa. Cut sections of 1⁄16" balsa sheeting and use CA glue when sheeting the two corners. Shave off the edges of each layer added. This will allow you to see how much more is needed and how wide the next sheeting layer should be.
Test to make sure the Engine is pushed forward enough to give clearance for the Spinner, by placing the backplate of the Spinner against the Engine Thrust Washer. Insert a scrap of ply (the same thickness as F1A) between the Backplate and F1B. If there is not enough room, you will have to sand the Backplate (if it’s plastic) or the face of F1A and F1D after the Cowl construction is complete. A palm sander or similar tool would achieve this in a balanced fashion.
Main Landing Gear Use a razor blade to cut beyond the laser-cut lines as shown above. To get access to the Undercarriage Mount, the Fairing must first be carefully cut out. The blade should cut in at 45˚ angle along the lengthwise cut. Carefully remove the Fairing, revealing the installed Blind Nuts. (Save this Fairing section for a later step.) The Blind Nuts will protrude to aid alignment of the Main Landing Gear.
Glue the Fairing assembly into the cut-out/saved Fairing section. Make sure the holes line up. Trim the corners of the Fairing assembly to match the cut line (otherwise the Fairing will not fit into the Fuselage). Place the Fairing over the Main Landing Gear while it is on the Fuselage, and mark the edge for minimal trimming. Final Touches Wheels Use a small scrap of cardstock pushed over the end of the axle. This will provide a gap that can be redeemed later.
Notes MosquitoBite Planes Robin 37
104 Malcolm St. Almonte, Ontario, Canada K0A 1A0 613-256-0008 © 2004-2007 MosquitoBite Planes All Rights Reserved www.mosquitobiteplanes.
