SkyBoy (600) - Stevens Aeromodel, LLC · ☐ 4 Channel radio and micro receiver. We suggest the Spektrum DX6i and AR500 receiver. ☐ 2 - HS-82MG servos ☐ 2 - HS-65HB servos ☐

SkyBoy (600)By Stevens AeroModel

Length 36 inches | Span 48 inches | Wing Area 640 inches2 | Flying Weight 36 oz.

Version 12/03/2010

SkyBoy 600 © 2010 Stevens AeroModel all rights reserved. Page 1 of 55

Product Support


WARRANTY

Stevens AeroModel guarantees this kit to be free from defects in both material and workmanship at the date of purchase. This warranty does not cover any component parts damaged by use or modification. In no case shall Stevens AeroModel’s liability exceed the original cost of the purchased kit. Further, Stevens AeroModel reserves the right to change or modify this warranty without notice.

LIABILITY RELEASE

In that Stevens AeroModel has no control over the final assembly or material used for final assembly, no liability shall be assumed nor accepted for any damage resulting from the use by the user of the final user-assembled product. By the act of using the user-assembled product, the user accepts all resulting liability.

If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised to return this kit immediately in new and unused condition to the place of purchase.

THIS PRODUCT IS NOT INTENDED FOR CHILDREN 12 YEARS OF AGE OR YOUNGER

WARNING: This product may contain chemicals known to the State of California to cause cancer and or birth defects or other reproductive harm.

PRODUCT SUPPORT

This product has been engineered to function properly and perform as advertised with the suggested power system and supporting electronics as outlined within this product manual. Product support cannot be provided nor can Stevens AeroModel assist in determining the suitability or use of electronics, hardware, or power systems not explicitly recommended by Stevens AeroModel.

For product assembly support, replacement parts, hardware, and electronics to complete this model please contact Stevens AeroModel on-line at www.stevensaero.com.

Stevens AeroModelPO Box 15347 - Colorado Springs, CO 80935 - USA

719-387-4187 - www.stevensaero.com

http://www.stevensaero.com

http://www.stevensaero.com

Project Checklist

Kit Contents

Major Components☐ Laser cut wood (29 Sheets - See inventory on following pages)☐ Illustrated instruction manual☐ 1 - Pre-Bent landing gear (1/8 in. dia. wire)☐ 1 - Laser cut wind screen☐ 1 - Laser cut color profiles for pilot figure

Strip Wood☐ 2 - 3/8 in. square x 36 in. balsa stock (Leading Edge)☐ 3 - 1/4 in. square x 36 in. balsa stock (Main Spar Cap Strips)☐ 4 - 3/16 in. square x 36 in. balsa stock (Turbulator Spars, Fuselage and Aileron Stiffeners)☐ 2 - 1/8 in x 3/16 in. x 36 in. balsa stock (Sub Spar Stiffener)

Long Hardware☐ 2 - 18 in. x 1/32 in. inside dia. plastic pushrod housing [SUL-S98117]☐ 2 - 18 in. x .032 wire [SUL-S97253]☐ 1 - 18 in. x .045 wire [SUL-S97254]☐ 2 - 12 in. x 1/2 in. paper tube

5 x 8 Hardware Bag☐ 6 - #32 rubber bands☐ 4 - Razor Control Horns [DUB936]☐ 3 - 3/16 in. x 4.5 in. hardwood dowels☐ 2 - Wing Tip Skids [DUB990]☐ 1 - Pkg Large Rubber Bands [HBZ7127]☐ 1 - 3/4 in. tailwheel☐ 1 - Pkg 1/8 in. wheel collars [DUB139]☐ 1 - 1/32 in. laser cut ply grill (Part F16)☐ 1 - 1/16 in. laser cut ply wing trailing edge reinforcement (Part W9)☐ 1 - 3/16 in. laser cut basswood elevator joiner (Part E6)☐ 1 - Hardwood landing gear block cut to 2-5/8 in. length [SIGSH655]

3 x 2 Hardware Bag☐ 4 - 4-40 Blind Nuts☐ 4 - 4-40 x 1/2 in. Pan Head Machine Screws☐ 4 - 0 x 3/16 in. Screws☐ 4 - Micro E/Z Connectors [DUB845 2 pkgs]☐ 4 - CA Hinge [SIGSH710M]☐ 4 - 3/16 in. dia. x 1/16 thick Neo. Magnets☐ 2 - Micro E/Z Links [26310]☐ 2 - Micro II E/Z Links [27805]☐ 1 - 1 in. length Silicone Tube


Required Electronics (Available at StevensAero.com)

☐ 4 Channel radio and micro receiver. We suggest the Spektrum DX6i and AR500 receiver.☐ 2 - HS-82MG servos☐ 2 - HS-65HB servos☐ 2 - 12” Servo Extensions☐ SA Sport BL.10 Motor [SUPA2418-8]

For 11.1V power system use: ☐ Thunderbird 36 36Amp ESC [CSETB36]☐ 11x5.5E Propeller [APC12060E]☐ Hyperion G3 7.4V 2100mAh 3 cell LiPo Battery [HP-LG325-2100-3S]

For 7.4V power system use: ☐ SA Sport - 30Amp ESC [SUP30AESC]☐ 12x6SF Propeller [APC12060SF]☐ Hyperion G3 7.4V 2100mAh 2 cell LiPo Battery [HP-LG325-2100-2S]


Required Building Supplies and Tools

☐ Pair 4-1/2 in. Big Lite Wheels [DAV5740]☐ 1 oz. Medium CA Glue☐ 1/2 oz. Thick CA Glue☐ 1 oz. Thin CA Glue☐ CA glue accelerator (kicker)☐ Balsa filler☐ Hobby Knife with ample supply of #11 blades☐ Sanding block with 400 and 600 grit paper☐ Heat Gun and Covering Iron☐ Small Needle Nose Pliers☐ 1 in. x 12 in. length sticky back velcro

☐ 3/4 in. wide clear tape☐ 2 Roll AeroLITE (solite)☐ 1 Roll AeroTRIM (solartrim)

Suggested Building Supplies

☐ CA glue de-bonder☐ Long sanding bar☐ Razor Plane☐ Low Tack Painters Masking Tape

Laser Cut Parts Inventory










General Assembly Instructions

Thank you, for purchasing this Stevens AeroModel SkyBoy (600)™. The SkyBoy (600)™ was inspired by our good friend Kris Cartwright who brought in a sketch of a low wing companion plane for our SkyBuggy. With an obvious tip of the hat to Andy Clancy and his “Bee” series of models, along with it’s nostalgic lines, the SkyBoy (600)™ was just too good not to share with the R/C modeling community. SkyBoy (600)™ is a gentle flyer suitable for the intermediate pilot, and we’re sure you’ll have many hours of pleasure flying at the local park or school yard. SkyBoy (600)™ has been developed and manufactured using state of the art CAD/CAM systems and features a unique interlocking construction process that, when compared to traditional methods found in other model aircraft kits, save countless hours of measuring, cutting, sanding, and fitting. We are certain that you’ll find our kit to offer a truly exceptional build experience. As this kit is recommended for the novice model builder and “pilot”; we invite absolute beginners to correspond with us, or to seek the help of another seasoned builder. At any time should one run across a term or technique that is foreign please don’t hesitate to contact our staff with your questions.

Please READ and RE-READ these instructions along with any other included documentation prior to starting your build and or contacting our staff for builder support.

Pre-sanding

Do not skip this step. Prior to removing any parts from the laser cut sheet wood use a sanding block loaded with 250-400 grit paper and lightly sand the back side of each sheet of wood. This step removes any residue produced as a result of the laser cutting process and, as we have found that most stock wood sizes run several thousandths of an inch over sized, slightly reduces the thickness of each sheet.

Leave your pre-sanded parts in the sheet until required in the assembly process.

Protecting your worktable

Use the poly tube that this kit was shipped in as a non-stick barrier between your worktable and the product assembly. Promptly clean up any epoxy spills with rubbing alcohol and a disposable towel.

Bonding the assembly

As this product tabs, notches, and otherwise interlocks like a 3D puzzle we suggest that when fitting parts you dry fit (use no glue) the parts together first. It’s advised to work 1-2 steps ahead in the instructions using this dry-fit technique which allows ample opportunity to inspect the fit and location of assembled components and realizes a benefit as each successive part contributes to pulling the entire assembly square. Once you arrive at the end of a major assembly step(s) square your work on top of a flat building table and revisit the dry fit joints with glue. Using the dry-fit process you’ll be able to recover from a minor build mistake and will ultimately end up with a more square and true assembly.

Unless otherwise noted in the instructions, always use medium CA glue for bonding parts.

Never force the fit!

Remember this is a precision cut kit our machines cut to within 5 thousandth of an inch in accuracy. Yet the wood stock supplied by the mill may vary in thickness by up to 20 thousandths. This variance in the wood stock can cause some tabs/notches to fit very tight. Hey, dad always said it was easier to take away material than add it back. With this in mind, should you find a joint to fit rather snug consider lightly sanding a tight fitting tab rather than crushing and forcing your parts together. You’ll break fewer parts in assembly and will end up with a more square and true assembly.


Tail Feathers☐ Horizontal Stabilizer: Begin by fitting HS1a

and HS1b together to form HS1. Bond with thin CA

☐ Bond part HS2 to HS1 assembly

☐ Bond parts HS3 to each end of HS2

☐ Bond HS4 to HS1 assembly and parts HS3 to complete outer frame.

☐ Bond cross piece HS5 and “B” diagonals to each side to complete Horizontal Stabilizer.

☐ ☐ Elevator: Build one half at a time. Start by bonding E1 to E2.


HS1a

HS1bHS4

HS2

HS3

HS3

HS2

HS1

HS3

HS3

HS5

E1

E2

HS1

“B” Diagonals

Tail Feathers Cont.☐ ☐ Bond E3 to E2.

☐ ☐ Bond E4 to E3 and E1 to complete outer frame.

☐ ☐ Bond E5 and “C” diagonals to complete Elevator half. Repeat previous ☐ ☐ steps to build second half.

☐ Using a straight edge as a guide, join Elevator halves with hardwood part E6. Bond with medium CA.

☐ Vertical Stabilizer: Bond parts V1, V2, and V3 together to form Vertical Stabilizer frame.

☐ Rudder: Using a short length of .045 wire, scrape out the etched areas on parts R1 and R2 to create a recess for the tail wheel wire. The recess should be just deep enough for the .045 in wire to seat snuggly.


E2

E3

E1

E3

E4

E5

E6

V1 V2

V3

R2

Straight Edge

“C” Diagonals

Tail Feathers Cont.☐ Bond parts R1 and R2 together with thin CA.

☐ Bond R3 to R2.

☐ Bond R4 to R3.

☐ Finally bond R5 to R4 and R1 to form Rudder outer frame.

☐ Bond part R6 and “A” diagonals to complete Rudder Frame.

☐ Tailwheel: Cut a length of .045 in. wire to 5-1/2 in. long.


R1

R2

R2 R3

R3

R4

R5R1 R4

R6

“A” Diagonals

5-1/2 in. Long

Tail Feathers Cont.☐ Make a 90 degree bend 1-1/8 in from one

end.

☐ 7/8 in. from the first bend, make a 45 degree bend.

☐ Two inches from the second bend, make another 45 degree bend, 90 degrees from the plane of the first two bends.

☐ Make another 45 degree bend 1/4 in. from the last bend.

☐ Make a 90 degree bend 1/2 in. from the last bend.

☐ Trim any excess wire 1/2 in from the last bend.


A

1-1/8 in.

AB

7/8 in.

A

BC2.0 in.

DC

1/4 in.

C D E

1/2 in.

E1/2 in.

DC

Fuselage Construction☐ Mount the provided 3/4 in. tailwheel.

☐ Bend end of wire over to retain wheel.

☐ Fit tailwheel wire to recess in parts R1 and R2 of Rudder. Secured with medium CA.

☐ Using thick CA, bond R7 to base of rudder, trapping wire. Ensure holes for rudder horn line up and are not fouled with glue.

☐ Bond remaining R7 to the other side of the Rudder with thick CA.

☐ Bevel leading edge of rudder and elevator at a 45 degree angle.


45 deg.

R7

R2

R1

R7

45 deg.

Fuselage Construction☐ Crutch Assembly: Fit F1 crutch to F2

former. Tack glue with a small amount of medium CA.

☐ Bond F3b to bottom of F3 with thin CA.

☐ Slide F1 through lower part of F3, up to the notches behind F2.

Carefully twist F3 into place.

Tabs on F3 will rest on top of F1 crutch. DO NOT GLUE.

☐ Fit F4 to slots in F1 just behind F3. Prongs on F4 point in the same direction as the tops of F2/F3. DO NOT GLUE.


F1F2

F3

F3b

F3

F2

F1

F2F3

F1

F1

F4

Top

Top

Up

Top Tab

Top View

Top View

Fuselage Cont.☐ Bond F5b to bottom of F5 with thin CA.

☐ Slide F1 through F5 and carefully twist into place.

Ensure tabs seat firmly on F1 - one on the top, the other below. DO NOT GLUE.

☐ Bond F6b to bottom of F6 with thin CA.

☐ Fit F6 to taps at the end of F1. DO NOT GLUE.

☐ The completed fuselage crutch assembly should appear as below. Ensure that all formers are positioned correctly, with their tops up then tack glue with medium CA.


F5

F5b

F6

F6b

F5

F1

F6

TopTop View

Tab

Tab

TopF6F2 F3

F4F5

Fuselage Cont.☐ Fuselage Doubler: Build right side first.

With etching facing up, fit FDa, FDb (RIGHT), and FDc together and bond with thin CA.

☐ On a smooth, flat surface, fit FDd (RIGHT) to previous assembly. Ensure that etching on all parts face up.

☐ Ensure pieces are flush with table top. FDa,b,c assembly will stand proud of FDd by 3/32 in. bond with thin CA.

☐ With etching on fuselage doubler facing up, fit fuselage crutch to doubler.

☐ Ensure tabs on crutch extend through forward part of doubler 3/32 in. as shown. Tack glue crutch to doubler with medium CA.

☐ Cut longeron from 18 in. length of 3/16 in. square balsa to and fit to slots in formers and fuselage doubler. Tack glue at formers F2 and F3 only.


Right Side

FDa FDb FDc

FDd

FDa,b,c

Glue HereLongeron

F2

F3

Top

Bottom(RIGHT)

3/32 in. Proud

Fuselage Cont.☐ Longeron will touch the top of F4 - DO NOT

GLUE.

☐ Allow longeron to extend past F6 a little. This will be trimmed later. DO NOT GLUE.

☐ Fuselage Side: Fit and bond parts FSa and FSb together with thin CA.

☐ ☐ Fit and bond FSc to FSb.

☐ ☐ Fit and bond FSd to FSc and FSb.

☐ ☐ Fit diagonal braces in slots in fuselage side.


F4

Longeron

F6

Longeron

FSa

FSb

FSa

FSb

FSc

FSc

FSb

FSd

Diagonals

Fuselage Cont.☐ ☐ Ensure that numbers on the ends of the

diagonals match the numbers on the slots. Bond with thin CA.

☐ Test fit completed fuselage side to crutch/doubler assembly. Ensure, and familiarize yourself with, the fit of all parts.

☐ Remove fuselage side and coat doubler with thick CA then...

...immediately re-fit fuselage side pressing doubler/side together on a flat surface.

☐ Hold assembly on a flat surface and bond all mating surfaces with medium CA.

☐ Motor Mount: With the etched (back) side facing up, drive the four blind-nuts in the circled holes of F7 with a hammer.


3

3 3

BACKF7

F2

Fuselage Cont.☐ Bond blind-nuts with thin CA at each nut

flange.

☐ Fit motor mount F7 to fuselage side. Ensure that flanges of blind nuts face the rear of the fuselage. Tack glue in place.

☐ Prep for Left Side: Trim previously installed longeron flush with the back of F6.

☐ Fit and tack glue F8 to right fuselage side, trapping longeron.

☐ Left Fuselage Doubler: With etching facing up, fit and bond together parts FDa,b,c (Left).

☐ On a smooth, flat surface, fit FDd (Left) to previous assembly. Ensure that etching on all parts face up.


F7

FDd

F6

FDc FDb FDa

Left Side

Bond

Trim

Do Not Cut Through Fuselage Side!!

F8

(LEFT)

FDa,b,c

Fuselage Cont.☐ Ensure pieces are flush with table top.

FDa,b,c assembly will stand proud of FDd by 3/32 in. Bond with thin CA.

☐ Fit and tack glue doubler to fuselage crutch. Tabs on F1, F2, F3, and F7 will stand proud of doubler.

☐ Fit left longeron. Glue to F2 and F3 - Do not glue to any of the other formers.

☐ Allow longeron to extend past F6 a little. This will be trimmed later. DO NOT GLUE.

☐ Fuselage Side: Refer to ☐ ☐ steps on pages 14 and 15, and complete the second fuselage side in the same manner.

☐ Temporarily fit fuselage side and check alignment and fit of all tabs.


F6

Do Not Glue

Longeron

Glue

Tabs Stand Proud

Longeron

F1F7

F3F2

Fuselage Cont.☐ Remove fuselage side and coat doubler with

thick CA then...

...immediately re-fit fuselage side pressing doubler/side together on a flat surface.

☐ Hold assembly on a flat surface and bond all remaining mating surfaces on the left side with medium CA.

☐ Trim left longeron flush with rear of F6.

☐ Aft Fuselage: Fit and tack glue F9 to one fuselage side.

☐ Bring sides together and tape, fitting and tack gluing F9 in place. Do not glue aft and of fuselage at this time.


F6

Bottom View

F9

Top View

Do Not Glue

F9

Tape

Fuselage Cont.☐ Fit F13 to aft bottom of fuselage. Tack glue at

F6, then continue along sides, pulling together and tack gluing as you go.

☐ Fit F9a through hole in F10.

☐ Carefully twist F9a into place.

☐ Fit and tack glue F9a/F10 assembly to top rear of fuselage.

☐ Fit and bond one part F12 to F9a and F10.

☐ Fit and bond the other part F12, creating a pocket for the vertical stabilizer. The rear portion of F12 will overhang the fuselage sides slightly. This will be sanded off later.


Bottom View

F13

Top View

F9a

F10

F10

F9a

F9a

F10

F12

F12

Overhang

F9a

F10

Fuselage Cont.☐ Fit and bond one part F11 to F10

☐ Fit and bond second F11 to F10, creating a support for F6a.

☐ Fit and bond F6a to F11 supports and F10.

☐ ☐ The rear stringers are numbered 1, 2, and 3. Fit and bond one stringer 1 into top slots in F6a and F9a.

Slot numbers correspond with stringer numbers.

☐ ☐ Fit and bond remaining stringer number 1 on the other side.


F11

F10

F11

F10

F6aF10

Stringer 1

Stringer 1

F6a

F9a

F6a

Stringer 1

11

2

3

2

F9

F9

Top View

Top View

Top View

Fuselage Cont.☐ ☐ Gently squeeze the rear of the stringers

against the F12’s and bond in place.

☐ Repeat previous steps marked ☐ ☐ to install stringers 2 and 3.

☐ Fit and bond a 4-1/2 in.length of 3/16 in. square balsa in slots in the top of F6a and F9a. Do not allow piece to extend into pocket for vertical stabilizer.

☐ Align extreme end of fuselage sides and bond with medium CA.

☐ Bond all mating surfaces in the rear fuselage with medium CA.

☐ Sand forward ends of stringers flush with F6a


F12

Stringer 1

2

3

3/16” square Balsa

F6a

F9a

F6a

Stringer 2 stands proud of 1 and 3

Fuselage Cont.☐ Sand F12 overhang flush with fuselage sides.

☐ Tape cockpit sheeting CS in place aft, and flush with the face, of F8. TIP! - Wet the outside of the sheet with a little glass cleaner to aid in forming it around the fuselage.

When sheeting in in position and dry, bond it with thin CA.

☐ Repeat the process for the nose sheeting NS, positioning it between F2 and F3.

☐ Assemble and bond the hatch catches from parts Ca and Cb.

☐ Insert a neo-magnet in each catch assembly. Bond from the back with medium CA.


F8CS

F2

NS

Ca Cb

Neo-Magnet

Top View

Top View

Fuselage Cont.☐ Fit and bond catches on F3 and F8 within

hatch area.

☐ Nose: Tab and bond part N1 into F2 and onto motor mount.

☐ Align N2 within etched box on N1. Remove N2, coat N1 with medium CA and replace N2.

☐ Repeat process with parts N3 through N6, creating a “wedding cake” that will later be shaped into some pleasing curves.

☐ Fit and bond hardwood landing gear mount in slots in fuselage doubler. The groove should line up with the slots in the fuselage sides.

☐ Fit and bond F14 to F3, overlapping landing gear mount, but not the groove.


F8

N2

N1

F2

F14

Top View

Top View

Top View

Bottom View

Bottom View

Fuselage Cont.☐ In the same manner fit and bond F15,

creating a slot for the landing gear wire to fit

☐ With medium Ca, bond straight end of ply grill F16 to former F2 and F15 with medium CA.

☐ Coat edges of recessed fuselage doublers with thick CA and lay the grill down between fuselage sides. Hold in place with tape until CA sets.

☐ Hatch: Begin hatch by fitting parts H2 to H1.

☐ Join assemblies with spine H3

☐ Fit former H4 to spine H3. Square on a flat surface and bond all parts with thin CA.


F14

F15

F15

F16

F15

F16

H2

H1

H3

H4

H3

F2

Fuselage Cont.☐ Insert a neo-magnet into each H2. Check

and double check polarity before gluing in place. Ensure magnets are oriented so they attract the magnets in the catches, and close the hatch properly. Bond with medium CA.

☐ Fit and bond assembly to hatch base H5.

☐ Fit one half of hatch sheeting HS to spine H3.

☐ Align edge of HS down the center of spine H3 and tack glue with thin CA.

☐ Wet sheeting, wrap around formers and tape in place. Allow to dry. Ensure assembly is square and tack glue sheeting in place.

☐ Repeat process to attach the other half of HS.


Neo-Magnet

H5

HS

H3

HS

H3

Fuselage Cont.☐ Double check that assembly is square and

flat, then permanently bond sheeting.

☐ Check it out! Your fuselage is almost complete!

☐ Pushrod Housing: NOTE - the following steps will be done with the fuselage inverted. Insert an 18 in. length of yellow pushrod housing through the rear-most slot on the RIGHT side of the fuselage.

☐ Pass pushrod housing through the furthest LEFT hole in F9...

☐ ...through left hole in F6...

☐ ...and finally 1/8 in. through left hole in F5. Bond housing at each former and at the exit point in the fuselage side with a drop of medium CA.


Bottom View

Bottom View

Bottom View

Bottom View

F9

F6

F51/8 in.

Right Side

Left

Left

Left

Fuselage Cont.☐ Insert another 18 in. length of pushrod

housing through the forward hole in the LEFT fuselage side.

☐ Cross over previous pushrod housing, then through the inner hole on the RIGHT side of F9.

☐ Pass the housing through the RIGHT holes in F6 and F5, leaving 1/8 in. extending beyond F5. Bond at each former and fuselage exit.

☐ Trim pushrod housings flush with fuselage sides.

☐ Final sand your fuselage. Round the nose to a pleasing shape, and round off the edges of the fuselage, leaving the wing saddle area square.


Bottom View

Bottom View

Bottom View

F5F6

Left Side

Right

Right Side

Trim

Wing Construction☐ Assemble main spar from part W1a and two

parts W1b. Bond with thin CA.

☐ Fit ribs R1 to center slots of main spar and tack glue.

☐ Cut a piece of 1/4 in. square balsa stock to 26-1/4 in. long to create the lower spar cap. align ends with etch marks on W1 and fit into slots in R1’s. DO NOT GLUE.

☐ Assemble trailing edge from from part W2a and two parts W2b. Bond with thin CA.

☐ Fit ribs R1 to center slots in trailing edge W2 and tack glue.

☐ Fit ribs R2 to main spar and trailing edge, tack gluing in place.


W1a

W1b

R1

W2a

W2b

W2b

W2

R2

R2

R1

W1

Etch Mark

Cap Strip

Wing Cont.☐ Fit and tack glue ribs R3 to main spar and

trailing edge.

☐ Insert gussets W3 between ribs R1 and trailing edge W2.

☐ Repeat gussets for ribs R3 and trailing edge W2. Square wings on a flat surface and bond W3’s in place.

☐ Cut upper spar cap from 1/4 in. square balsa, 26 in. long. Fit into slots on top of ribs, centering ends in the middle of ribs R3.

☐ ☐ Slide diagonal brace W4 through slot in sub-rib R1a. DO NOT GLUE.

☐ ☐ Fit sub-rib R1a to main spar. Tack glue R1a to main spar only.


R2

R1

R3

W3

W3

R1

W2

W3

W2

R3

Upper Spar Cap

Center of Rib

W4

R1a

R1a

W4

Tack Glue

Wing Cont.☐ ☐ Fit W4 into the corner of R1 and main

spar, between upper and lower spar caps. Tack glue with medium CA.

☐ ☐ Fit and tack glue sub-rib R2a to main spar.

☐ Repeat ☐ ☐ steps on page 34 and above for opposite side diagonal brace.

☐ Assemble turbulator spar T1 from parts T1a and T1b. Bond with medium CA.

☐ Fit and tack glue turbulator spar to front notches in the ribs.

☐ Cut remaining spars from 36 in. lengths of 3/16 in. square balsa stock. Trim so that spar ends align with the center of ribs R3 when spar is centered.

☐ Install spars to middle and aft notches of the ribs. Square wing on a flat surface and bond all spars to each rib with medium CA.


W4

R1

Spar Caps

R2a

T1a

T1b

Front Notch

Center of Rib R3

Install

Wing Cont.☐ Cut leading edge from 3/8 in. square balsa

stock. Trim so that ends align with the center of ribs R3 when leading edge is centered.

☐ Install leading edge to forward tips of ribs. Center leading edge, and square wing on a flat surface. Bond with medium CA.

☐ Cut paper tubes to 12 in. lengths. Slide tubes through holes in aft portion of ribs R1, R2, and R3.

☐ Center tubes so that they extend slightly beyond ribs R1 and R3. DO NOT BOND.

☐ Square wing on a flat surface and glue W4’s to leading edge and notch in rib R1a. Bond all mating surfaces between spars, cap strips, ribs, leading & trailing edges with medium CA.

☐ Assemble center sheeting S1 from parts S1a and S1b. Bond with thin CA.


Leading Edge

Leading Edge

Center of Rib

Paper Tube

W4

Leading Edge R1a

S1a

S1b

R1/R3

Extend

Wing Cont.☐ Install S1 on bottom of ribs R1, between

leading edge and lower main spar cap strip. Bond with thin CA.

☐ Assemble center sheeting S2 from parts S2a, S2b, and S2c. Bond with thin CA.

☐ Fit and bond S2 on bottom of ribs between trailing edge, lower spar cap strip, and ribs R1.

☐ Assemble center sheeting S3 from parts S3a, S3b, and S3c. Bond with thin CA.

☐ Fit and bond S3 to top of ribs between trailing edge, upper spar cap, and ribs R1. With S3 now installed, Bond paper tubes within wing assembly using medium CA glue.

☐ Press S3 flat against trailing edge and bond with thin CA.


S1

Leading Edge

Spar CapR1

S2a

S2b

S2c

S2

Trailing edge

Bottom View

Bottom View Spar Cap

R1R1

S3a

S3b

S3c

R1R1

Trailing edge

S3Spar Cap

Top View

S3

Trailing edge

Wing Cont.☐ Bond ply brace W9 in slot in trailing edge.

☐ Sand S3 sheeting to a taper so that it flows smoothly into trailing edge.

☐ ☐ Wing Tip: The steps marked ☐ ☐ will be repeated to build the second wing tip. Prop up one end of the wing so that outer spar rests flat on the table.

☐ ☐ Fit and tack glue rib R4 to spar

☐ ☐ Fit and tack glue sub-spar W5 to ribs R3 and R4. Square wing tip and bond ribs to spars with medium CA.

☐ ☐ Cut lower spar cap from 1/4 in. square x 5-7/8 in. long balsa stock. Tack glue at ribs only.


W9

S3

R4

R4R3

W5

Main Spar

Lower Spar Cap

Wing Cont.☐ ☐ Cut upper cap strip from 1/4 in. square x

5-11/16 long balsa stock. Tack glue at ribs only.

☐ ☐ Tack glue sub-rib R3a to spar.

☐ ☐ Fit turbulator spar T2 to ribs R3, R3a, and R4. Ensure arrow on T2 points toward rib R3. Tack glue.

☐ ☐ Cut remaining turbulator spars to length from 3/16 in. square balsa stock. Spars should end flush with outer face of rib R4.

☐ ☐ Cut leading edge from 3/8 in. square balsa stock, 8 in. long. Sand one end of stock to fit center section leading edge at rib R3. Tack with thin CA.

☐ ☐ Fit ply servo pocket part W6b to slots in Rib R3 and sub-spar W5. Bond with medium CA.


Main Spar

Upper Cap Strip

R3a

R3

R4

R3a

T2

R4

8 in.

R3

W6b

W5

R3

Bottom View

Wing Cont.☐ ☐ Fit balsa servo pocket part W6a over

W6b, keying into slots in R3 and sub-spar W5. Bond with medium CA.

☐ ☐ Cut lower stiffener for W5 from 1/8 in. x 3/16 in. balsa stock. Fit and tack glue at slots in rib R3 and servo pocket part W6a.

☐ ☐ Cut upper stiffener for W5 from 1/8 in. x 3/16 in. balsa stock. Fit and tack glue at slots in ribs R3 and R4.

☐ ☐ Assemble wing tip sheeting W8 from parts W8a, W8b, and W8c. Bond with thin CA.

☐ ☐ Tack glue tip sheeting W8 in place, fitting tabs and slots to those in W5 and R4.

☐ ☐ Roll sheeting forward, tack gluing as you go, fitting into slots/tabs on forward part of rib, spar tab, and leading edge. Square wing tip on a flat surface and bond all mating surfaces with medium CA.


W6a

R3

W5

Bottom View

Bottom View

Top View

Stiffener

R3 W6a

W5

W5

R3

Stiffener

R4

W8a

W8b

W8c

W8

W5

R4

Wing Cont.☐ ☐ Sand leading edge to flow with wing tip in

a straight line. Do not round off.

☐ ☐ Soak a 14 in. length of 1/8 in. x 3/16 in balsa stock in warm water for a few minutes to soften. Lay 3/16 in. face against tip sheeting at W5 and secure with masking tape.

☐ ☐ Bend strip forward, a little at a time, towards leading edge, securing with masking tape as you go. Allow to dry.

☐ ☐ Tack glue cap strip between tapes. Remove tape then bond with medium CA.

☐ ☐ Trim and sand cap-strip flush with W5 and leading edge. Do not round off.

☐ ☐ Sand top of cap strip flush with tip sheeting.

☐ With wing held flat on your building surface revisit all tack glued joints and spar cap to spar joints with CA glue.


W5

Wing Cont.☐ Repeat steps marked ☐ ☐ beginning on

page 34 to built second wing tip.

☐ ☐ Ailerons: Begin by tack gluing rib A3 to spar A6 as shown.

☐ ☐ Next, tack glue Rib A4 in the middle slot in A6.

☐ ☐ Then tack glue the shorter rib A5 to A6.

☐ ☐ Fit trailing edge A1 to ribs. Square aileron on a flat surface and bond all parts with medium CA.

☐ ☐ Fit control horn plate A2 to trailing edge A1, rib A3, and spar A6. Bond with medium CA.


A3

A6

A6

A4

A6

A5

A1

A6

A1

A2A3

Wing Cont.☐ ☐ Fit and bond tip A7 to rib A5 and spar A6.

☐ ☐ Cut spar stiffener from 3/16 in. sq. balsa stock 5-13/16 long. The stiffener will extend flush with the outer face of rib A3. Fit and bond stiffener to top of all three ribs.

☐ ☐ Soak a length of 1/8 x 3/16 x 6-1/2 in balsa stock in warm water to soften. Tape 3/16 in. face of wood against trailing edge and aileron tip A7. Allow to dry.

☐ ☐ Tack glue cap strip to tip A7. Remove tape then bond with medium CA.

☐ ☐ Using a razor plane and/or sanding block, reduce stiffener until it is flush with top surface of ribs and top of spar.

☐ ☐ Sand A7 flush with face of spar A6.


A6

A5

A7

A7

A7

A3

5-13/16 in.

Wing Cont.☐ ☐ Sand bottom of trailing edge to flow

smoothly into tip. Round tip, leave trailing edge square.

☐ Repeat steps marked ☐ ☐ beginning on page 37 to build opposite aileron.

☐ Use a razor plane and sanding block to round off leading edge.

☐ Use the wing saddle profile in the fuselage to check the contour of the leading edge.

☐ Round leading edge into the wing tip. Round edges of the wing tip cap strip. Leave trailing edge of wing square.


Check Fit

Optional Float Mount☐ Provided in the kit is a ply plate that may be

added to the fuselage to provide a hard point for installing a float system.

☐ Coat one face with thick CA. Insert mount plate through F6 or through side of fuselage.

☐ Plate fits against the fuselage bottom behind F6, between the fuselage sides. Press in place and allow CA to cure, bonding mount firmly to fuselage bottom.

☐ After covering the fuselage, the bottom and mount may be drilled out to suit the mounting system and floats of your choice.


Bottom View

F6

F6

Finishing☐ Cover your model with a light weight, high

quality material such as StevensAero AeroLite or AeroFilm.

☐ Make pushrods from the provided .032 x 18 in. wire.

☐ Make a 90 degree bend 3/16 in. from one end.

☐ Fit the straight end into the push rod housing in the radio compartment.

☐ Feed the wire through, carefully puncturing the covering at the exit point.

☐ Remove wire then re-insert from the exit point, so that the bent end remains outside of the model.


Bottom View

Finishing Cont.☐ Using the “four armed” control horn from an

HS-82MG servo, attach a Mini E/Z Connector [DUB845] to the outer hole of one arm.

☐ Use your transmitter to electronically center servos. Install control horns so that E/Z Connectors are positioned opposite each other, 90 degrees to the servo body, as shown.

☐ Install servos in radio compartment, and feed pushrods through the E/Z Connectors.

☐ Connect motor and ESC. Feed ESC and wiring though nose, below motor mount and through hole in bottom part of F3.

☐ Fit a 4-40 x 1/2 in. machine screw in each of the holes on the left side of the mounting plate. Install three ply washers (from sheets 17 and 30) on each screw.

☐ Lightly thread the two screws into the motor mount. Install the remaining screws and tighten all to secure motor.


Bottom View

Finishing Cont.☐ Install a strip of 3/4 in. Velcro on top of F1, the

full length of the battery compartment.

☐ Install patches of Velcro on the bottom of F1 to provide mounting points for the ESC and receiver.

☐ Cut slots for hinging the tail surfaces. There should be a minimum of three on each side of the horizontal stabilizer and elevator, and three on the rudder, two on the vertical stabilizer, and one in the fuselage. Ensure all slots align with those on the opposite surface.

☐ Cut CA hinge material into pieces about 3/8in. x 5/8 in. You should be able to get three out of each CA hinge insert into slots.

☐ Join surfaces together, align, and bond hinges to surfaces with thin CA. Flex surfaces back and forth as CA cures to ensure free movement.

☐ Open holes in covering for the control horns using a warm pencil tip soldering iron.


Bottom View

Top View

Finishing Cont.☐ Install a control horn [DUB936] in the LOWER

LEFT side of the elevator, and the RIGHT side of the rudder. Glue horn in place.

☐ Fit the retaining plate on the posts on the opposite side of the surface. Glue in place, then melt posts in to “rivets” with a hot soldering or covering iron.

☐ Mount tail surfaces on fuselage, horizontal stabilizer first. Temporarily install main wing, and square tail surfaces with wing. Bond with medium CA along the seams.

☐ Cut a 1/8 in. long piece of the silicone tubing and slide onto pushrods.

☐ Connect pushrods to control horns with a Micro E/Z Link [DUB849].

☐ Safety the connection by sliding the silicone tubes over the E/Z Links.


Finishing Cont.☐ Center the rudder and elevator, electronically

center the servos, the tighten set screws in the E/Z Connectors, thus securing the pushrods.

☐ Open holes in fuselage for landing gear lug and wing mount dowels at leading and trailing edges, with a warm soldering iron.

☐ Paint dowels to match your covering. Center dowels in fuselage and bond with medium CA.

☐ Mount wheels on pre-bent landing gear with the provided wheel collars [DUB139].

☐ Retain landing gear with size 32 rubber bands. Wrap each band at least three times around gear wire and lug dowel.

☐ Tape windscreen in place just behind the hatch. Position so that it is centered, and the mounting holes are 3/32 in. below top edge of the sides.


3/32 in.

Hatch

Finishing Cont.☐ Mark location of holes with a fine tip marker.

☐ Remove windscreen and drill pilot holes with a 1/32 in. drill bit. Harden holes with a drop of thin CA.

☐ Peel protective coating from windscreen.

☐ Mount windscreen with provided 0 x 3/16 in. screws.

☐ ☐ Open holes in bottom of ailerons and insert a control horn [DUB936]. Bond with thin CA.

☐ ☐ Attach aileron with a strip of 3/4 in. clear tape, leaving a 1/32 in. gap all the way around aileron.


Tape

Finishing Cont.☐ ☐ Fold aileron back and apply another

length of tape on the inside, completing the hinge.

☐ ☐ Attach a 12 in. extension to a HS-65HB servo.

☐ ☐ Feed wiring through servo pocket and into paper tube within wing.

☐ ☐ Mount servo in pocket with control horn positioned away from aileron.

☐ ☐ Pull servo extension through the hole in the center of the wing.

☐ ☐ Using the long single armed control horn, install an E/Z Connector through the 1st or 2nd hole from the outside.


Tape

Finishing Cont.☐ ☐ Center servo electronically, then position

the control horn at a 45 degree angle to the servo, towards the wing tip.

☐ ☐ Cut a length of .045 wire 3-1/2 in. long. Make a 90 degree bend 3/16 in. from one end. Insert wire through E/Z/ Connector as shown.

☐ ☐ Cut a 1/8 in. length of silicone tubing and slide onto the pushrod.

☐ ☐ Connect pushrod to horn with a Micro 2 E/Z Link [DUB920].

☐ ☐ Secure connection by sliding the silicone tubing over the E/Z Link and pushrod. Repeat steps marked ☐ ☐ beginning on page 46 to install the other aileron servo.

☐ Open holes in trailing edge near aileron with a warm soldering iron. Mount wing skid [DUB990] and bond with thin CA.


Finishing Cont.

Flight Control Setup and Balance☐ First, mechanically and electronically center

all control surfaces and servos; Zero any trim settings in radio.

☐ Balance SkyBoy (600) 1/2 inch forward of the main spar. CG range will extend back to main spar, but for initial flights, keep it forward.

Control Surface Tavel - Given in degrees and set with a protractor gauge:

Rudder

Low Rate +/- 15 degrees 30% expoHigh Rate +/- 20 degrees 30% expo

Elevator


Ailerons


☐ Connect aileron wiring to receiver, and mount wing with the supplied large rubber bands.

☐ Congratulations! Your SkyBoy (600) is now complete. Run around in the back yard making propellor noises ‘til your neighbors call the cops.

Pre-Flight to First FlightHave an experienced pilot assist you with pre-flighting your new model. Just like having someone proof read something you’ve written, having a second fresh set of eyes to inspect your final product is often helpful in avoiding disaster.

While not an exhaustive pre-flight check, these are some of the major items that you should consider using when developing your own pre-flight check list. Get in the habit of always pre-flighting your models before each and every flight.

☐ Weight and Balance - Refer to the Flight Control Setup section for balancing your model correctly. Ensure that the SkyBoy (600)’s C.G. is in the appropriate location for your experience level.

☐ Check Weather - SkyBoy (600)’s first flight should be in zero wind conditions. SkyBoy (600) is capable of flying in winds up to 15 mph so long as the pilot is capable.

☐ Inspect Airframe for warps and obvious signs of wear and damage. Do not fly a damaged or warped model.

☐ Inspect Control Surfaces for center, proper direction of travel, proper throw, secure pushrod connections, hinges, and control hardware.

☐ Inspect Motor for proper direction of rotation, secure mounts and propellor. Check wiring, ESC, Receiver and Battery for secure mounting.

☐ Inspect Battery for full charge. Never begin a flight with a partially charged battery.

☐ Check Landing Gear - Repair or replace worn or rotten landing gear retention rubber bands. Check that tires are in good condition.

☐ Clear Area - Ensure that any spectators are well clear of the flight line. Have an assistant handy to keep people back and warn you of any impending danger (animals, unwary individuals, small children, etc.).


Pre-Flight Cont.☐ Clear Prop! - Before applying power to the

model, clear and keep clear of the prop arc. As electric motors are capable of inflicting severe damage (more so than their internal combustion counterparts) and may turn on unexpectedly anytime power is applied to the system. Respect the business end of the model (the prop and prop arc) treating every electric model and propellor as if it were a loaded gun.

☐ Go Flying! - Enjoy SkyBoy (600)’s smooth and docile flight characteristics. You will notice that SkyBoy (600) is a very stable airplane. When built straight, and trimmed for level flight, SkyBoy (600) should return to wings level from any attitude. We’ve found SkyBoy (600) to capture the imagination of pilots both young and old. With an experienced instructor and a buddy-box system, we’ve found SkyBoy (600) to be a very capable four channel sport plane.

If your first flight was a bit more exciting than you’d have liked, and your having problems with erratic flight performance; pleas inspect your equipment and airframe for damage, improper installation, and/or twists and warps. The most common mistakes are to try and fly with a warped or twisted wing. With such a fat chord and short moments, a small warp can cause big in-flight problems. Make certain that your wing is straight before you fly.

SkyBoy (600) has a great deal of side area. Coupled with the low wing, about 10 degrees of right thrust is required for stable flight. DO NOT ATTEMPT FLIGHT WITHOUT THE PROPER AMOUNT OF RIGHT THRUST! I know, it looks weird, but trust me, it’s necessary.

SkyBoy (600) is capable of all sport 4-channel aerobatics including Snaps, Cuban Eights, Wing Overs, Loops, Rolling Turns, and Inverted Flight.

☐ Have fun learning the in’s and outs of SkyBoy (600)’s in flight performance, and feel free to share your thoughts and experiences with our staff. We are committed to improving your build and flying experience and are constantly refining our processes, designs, and manuals to reflect customer feedback. You may correspond with Stevens AeroModel staff using any of the following methods:

E-Mail - [email protected]

RCGroups.com - Forum Build Threads.

Facebook.com - Search for Stevens AeroModel.

Phone - 719-387-4187 M-F 10A-5P MST


mailto:[email protected]

mailto:[email protected]

Documents

SkyBoy (600) - Stevens Aeromodel, LLC · ☐ 4 Channel radio and micro receiver. We suggest the Spektrum DX6i and AR500 receiver. ☐ 2 - HS-82MG servos ☐ 2 - HS-65HB servos ☐