Great Planes Ultra Sport 40 Kit - GPMA0410 - Manual (Page 17)

4. Cut the right wing tip loose from the wing and
use a Dremel Moto Tool to hollow out the wing tip. (This
will help to compensate for the weight of the engine head
and muffler).
cut a groove in the leading edge of the ailerons to
accept the torque rods. Cut these grooves a little larger
at the beginning, to make room for the torque rod
bearings. Trial fit the ailerons onto the torque rods and
cut or file as necessary until they fit.
5. Now securely glue the right wing tip in place.
6. Lay the ailerons on the plan and mark the hinge
locations on the ailerons. Place the ailerons against the
wing TE and transfer the marks over to the wing.
INSTALL AILERONS
NOTE: Do not glue the aileron hinges until after
your model has been covered.
7. Cut the hinge slots in the ailerons and wing TE
using an Xacto knife. (The suggested procedure is listed
below):
tapered balsa ailerons and the wing TE.
2. Check the length of your ailerons against the
actual aileron openings and trim the ailerons as neces-
sary. You should provide approximately 1/16" gap at
each end of the ailerons.
3. Lay the ailerons in place in the openings, with
the torque rods resting on top of the ailerons. Mark the
torque rod locations on the top of the ailerons.
1. Draw an accurate centerline along the LE of the
A. Begin by carefully cutting a very shallow slit in
the trailing edge at the hinge location. This first cut
is to establish your cut in the right place, so concen-
trate on staying on the centerline and don't cut too
deep!
B. Make three or four more cuts in the same line,
going slightly deeper each time. As you make
these additional cuts, work on going straight into the
wood. Continue this process while "wiggling" the
knife handle back and forth until the blade has
reached the proper depth for the hinge.
C. Trial fit the hinge into the slot. If the hinge is
difficult to push in, re-insert the knife and move it
back and forth in the slot a few times to enlarge the
slot.
8. IMPORTANT! Condition or "break-in" the
hinges by folding them back and forth several times.
9. Sand the leading edge of the ailerons to the same
4. Drill a 7/64" hole in the ailerons at the torque rod
"V"-shape as shown on the wing rib detail drawing.
locations, starting at the leading edge centerline and
drilling straight in to the proper depth.
10. Insert the hinges into the slots and trial fit me
ailerons in place on the wing. Do not glue the hinges un-
til after you have covered the wing.
There should be no hinge gap!
NOTE: Now is a good time to finish the wing tips.
Tape the ailerons on in the neutral position, and sand
the wing tips to blend with the ailerons.
5. Use the sharpened 1/8" diameter brass tube to
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