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US AirCore 40
Aircraft | Building | Flight-Log | Flying
Building Tips

Basically just folding plastic and a little cutting.  Align pieces and glue together with contact cement.  The wooden power-cartridge and wing spar epoxy together. The included video also helps get you started if you are unfamiliar with working with the corrugated plastic.

Looks like you can also build it as a tail-dragger, but I left mine with tricycle gear for now.

The engine, fuel tank, nose gear, and radio all install into a wooden platform called the Power Cartridge.  It then slides into place and is screwed into the fuselage rails.

I installed the receiver power switch at a 90° angle to the side. Then a paperclip bent with a "L" on one end and a loop/handle on the other. This switch actuator will exit the plane near the wings, and easily slides to and from the switch's hole when the "PC" is removed (look close at pics. to see it)

 

 

Landing Gear:

I used nylon bolts to hold the landing gear on instead of just using rubber bands. One pair of bolts should be right next to the inner landing gear wire (just behind it).

 

 

Landing Gear with Nylon Bolts

 

Mark and drill holes carefully, and not too close to the outsides.  On this one, hole centers were 1 1/4" apart (side-to-side), and 1 9/16" apart (front-to-back).
 
The screws don't hold well just screwed into the floor-board, so continue with the modification. 4 holes are marked and drilled into a small 3/16"x1 7/8"x2 1/2" plywood block that rides inside. Epoxy 4 matching blind nuts into the holes (double check your measurements).  If all goes well, just drop it in and use (4) 1/4-20x1" nylon bolts to mount the landing gear.  This whole procedure is only briefly mentioned in the manual.

Also notice the front landing gear "spring" is turned so that if the front wheel gets pushed aft (back), the spring gets tighter.

Anywhere wheel collars screw down, you should file a tiny flat spot on the wire or axle, but especially for the upper steering arm.
 

Protecting Paint:

The white and grey plastic AirCore material itself is completely fuel-proof, but the AirCore-40's paint job isn't.  To preserve the finish, use Flat Clear fuel-proof model paint (LustreKote) sprayed onto all areas with painted-on red and blue markings.
 

More Building Tips:

Aileron Servo mod.
Maintenance Record

Instruction Manual

 

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