Great Planes Ultra Sport 40 Kit - GPMA0410 - Manual (Page 35)

up with the fuselage centerline. Sand the dorsal fin to a
rounded shape, and blend it to the fin with balsa filler.
6. Screw the nylon aileron clevis connectors onto
the aileron torque rods.
INSTALL SERVOS, HORNS AND
PUSHRODS
NYLON AILERON CLEVIS AND CONNECTOR
1. Study the plans to determine the location of the
aileron servo cutout. Mark the location on the top of the
wing and cut an opening in the fiberglass and sheeting
slightly larger than your servo. CAUTION: Do not cut
into the wing spars or shear webs!
2. Remove a sufficient portion of the W-1 ribs to fit
your servo, leaving "shelves'' on which to glue the 1/8"
ply rails. (See the plan to determine the depth). NOTE:
A Dremel Moto Tool with a 1/8" router bit is excellent for
this, but it may also be done with an Xacto knife and a
long-nose pliers.
7. Attach the clevises to the clevis connectors,
then, with the ailerons in the neutral position, mark the
pushrod wires where they cross the holes in the servo
arm. Remove the pushrods and make a "Z-bend'' in the
rods at that point, using a "Z-bend pliers'' or a standard
pliers.
8. Remove the servo wheel from the servo and
workthe Z-bends into the wheel (NOTE: You may have
to enlarge the servo wheel holes with a 5/64" diameter
drill bit). Replace the servo wheel and check the opera-
tion of the ailerons. (See page 36 for the recommended
amount of aileron movement).
REMEMBER: Plan your servo installation care-
fully, as your setup may differ from the plans and photos,
depending on which engine you use, and whether you are
building a trike or taildragger.
9. Re-mount the elevator, rudder and throttle ser-
vos in the fuselage.
10. Hold the nylon control horns on the elevator
3. Make two servo rails from the 1/8" ply die-
cutting scrap, and glue them in place. (See the side view
of the aileron servo installation on the plan).
and rudder in the positions shown on the plan and mark
the mounting hole locations. Drill 3/32" holes at these
locations.
35
4. Mount the aileron servo using the screws pro-
vided with your radio.
5. Screw the nylon aileron clevises approximately
2/3 of the way onto the threaded end of the two 12" steel
wire pushrods.
control horns (on both sides of the control sur-
faces) by poking several holes with a pin, then
applying thin CA glue. Sand smooth.
11. Harden the balsa in the area of the