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Thank you for purchasing this Stevens AeroModel e-spresso laser cut indoor quickie racer. The e-spresso was designed to be simple to construct and fly thus the instructions are also very simple so we will not bore you with our typical illustrated 30-page manual. For more detailed information on the e-spresso we recommend you check our web site www.stevensaero.com
for the most recent version of this instruction sheet. Feel free to contact us with questions or concerns you may have at support@stevensaero.com
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Vitals
Span 24”
Length 17.5”
Area 110 Sq.”
Weight 3-4 oz.
Wing Loading 4.3-5.8 oz. / Sq’
Kit Contents
Laser Cut Parts Sheets (1*1/32” 2*1/16” 1*3/32”)
Instruction Sheet
Rolled Plan Sheet
Hardware Bag o 1 - Ply Parts Sheet o 3 - 1-1/2” length 1/8” dowel. o 1 - Cotter Pin o 1 - 24” length of pull-line. o 3 - .25” x 1/16” Aluminum Tube o 1 - 12” x 1/32” Piano Wire o 1 - #16 Rubber Bands (Bag of 10) o 2 - EDP50XC motor mount screws o 2 – Spindle Wheels
Recomended Finishing Hardware o 3 – Dubro 845 Mini EZ Connectors (2 pkg)
Recommended Radio Equipment
Plantraco DSP-4SC 8g receiver / 10A speed control combo
2 – 5g Sub-Micro Servos HES-2003 or HES-490
1 – ET-250 Lithium Polymer Battery 2 Cells 7.4v (or comparable Nimh / Nicad pack)
AZARR Micro Antenna
Required Building Materials to Complete the Model
Thin CA Glue
Clear Hinge Tape (Scotch)
Clear Poly Film for protecting the plan sheet
1 Roll light covering (Solar Film Solite or Nelson Lite Film)
Razor Blades and Fine Grit Sand-paper
Hot Glue Gun
General Assembly Tips
Review both the plan sheet and this manual prior to beginning any work.
Do not remove parts from the balsa sheet until they are required for assembly.
With parts still retained in sheets lightly sand both sides of the parts sheets to remove laser burns and smooth the wood.
The fit of these parts will be very snug thus all that is required for assembly is to key the components together and, while applying light pressure to hold parts in place, wick thin CA glue into the joints holding 2-3 seconds for a secure bond.

Tail Feathers
Assemble the horizontal stab from parts HS1 and HS2.
Assemble the vertical stab from parts VS1, VS2, and VS3.
An optional ruder VSv has been included and is not required either hinged or fixed for normal flight operation of the e-spresso (when operated as a 3ch model).
Sand a 45-degree bevel into the leading edge of the elevator part HS3 (optional HS3v) in preparation for top hinging with clear tape.
Final sand parts in preparation for covering.
Fuselage
Tip: When working with the fuselage we recommend you tack glue the joints at the tab and notch locations as you assemble the fuselage. Once the assembly is complete wick thin CA into all part-part surface joints.
Remove the fuselage sides from the balsa sheet there are two vertical braces imbedded within the aft fuselage section knock out. Install these braces to aft section of the fuselage in the notches provided (see plan sheet).
Locate the fuselage side with the word “inside” etched on it. Lay the fuselage side on your building board with
“inside” facing up. Install formers F2 and F3. Take the second fuselage side with the “SA” etching on it and key to formers F2 and F3.
Remove the part FT1 from the 1/32” balsa sheet install the cross brace (located in the central knock-out) to the notching provided in FT1. Install FT1 spanning the fuselage sides and the tops of formers F2 and F3.
Locate 1/32” Ply former F1A and test the fit of the EDP-50 motor to the hole provided in F1A. Sand the part if required. The fit should remain snug. Next, install ply former F1A and F1 to fuselage sides and FT1.
Install former FB1 spanning the bottom of the fuselage sides between F1A and F2.
Work fuselage side tabs into FT1 notches aft of the wing. Secure with thin CA.
Invert the fuselage so it rests on FT1. Lightly bevel the edges of the 1/32” balsa formers F4 and F5 and work into position from the fuselage bottom to FT1 and the fuselage sides.
Install FB2 spanning formers F3, F4, F5, and the fuselage sides do not glue the aft end of the fuselage together as the vertical stab will key in-between the fuselage sides.
Install 1/32” top former FT2 spanning the fuselage sides and former F5.
Test the fit of the Horizontal and Vertical Stabilizers to the fuselage. If required, sand lightly to achieve a positive fit.
Lightly sand fuselage in preparation for covering.
Wing
Tip: When working with the wing we recommend you friction fit as much of the wing together as possible then lay the assembly on your flat work surface and wick thin CA into all part-part surface joints.
Key ribs R1, R2, R3, R4, and R5 to the main spar S1.
Key the 1/32” LE1 leading edge jig to the leading edge of ribs R1-R5. Cap part LE1 leading edge jig with the
3/32” leading edge cap strip LE2. Double the center section of the leading edge by laminating the 3/32” balsa parts LE3 to both sides of LE1 in-between ribs R1.
Install R2B 1/32” ply rib doublers on either side of rib R2 to create the gear leg pocket.
Using the plan sheet as a guide, tack glue parts R1A to the main spar. Install S2 spanning R1A and R1.
Key the 1/32” trailing edge jig TE1 to the trailing edge of the wing assembly. Cap part TE1 with the 1/16” trailing edge cap strip TE2. Double the trailing edge at the center section by laminating the 1/16” balsa parts TE3 to both sides of TE1 in-between ribs R1. Double the backside of the trailing edge with the 1/32” ply part TE4 – laminate TE4 into position as indicated on the plan sheet.
Install the 3/32” turbulators spanning the length of the wing section.
Using the plan sheet as a guide, assemble WT1, WT2, and WT3 to create the wing tips. Tack glue the wing tips to the S1 spar at either end of the assembly. Bend the wing tip down to align with the centers of the leading and trailing edge and tack glue into position.
Lay the entire wing upon a flat surface and, with the wing-resting flat upon the riser jigs, begin securing each part joint with thin CA. Use the CA glue sparingly.
Install the part OPT1 (optional sport center aileron servo mounting pocket) to the wing center section of the underside of the wing assembly as indicated on the plan sheet.
Using a sharp razor – remove the rib riser jigs from the underside of each rib.
Sand a 45-degree bevel into the leading edge of the aileron parts A1 (optional sport ailerons A1v) In preparation for top-hinging using clear tape. Make a RIGHT and LEFT aileron.
Parts SB1 will only be used when flying with the single aileron option and are necessary to block the servo within the pockets created by S1A, S1, and S2 (reference plan sheet for detail).
Round the leading edge of the wing to blend in with the shape of the airfoil. Final sand the remainder of the wing in preparation for covering. Prior to covering the wing check the fit of the wing to the fuselage saddle. Sand as required achieving a positive fit.

Finishing the Model
Cover the fuselage, wing, and tail feathers using Nelson Lite Film or Solar Film Solite.
Cut two of the 1/8” dowels to 1-1/2” in length; round the edges and Install these wing retention dowels to the fuselage in the holes provided fore and aft of the wing saddle. CA in place.
Cut the third 1/8” dowel down to ¾” and install centered in the hole provided aft of former F5. CA in place.
Key the vertical stab through the notching in the horizontal stab (remove covering as required). Next, mount the entire tail assembly to the fuselage aligning the notches in the fuselage with the tabs in the assembly.
Temporarily fit the wing to the fuselage, secure with rubber bands, aligning the horizontal stab to run parallel to the wing and the vertical stab perpendicular to the horizontal. Secure the tail section components by running thin CA glue over the surface-to-surface joints (removing covering will not be required).
Hinge the Aileron and Elevator along the top surface using clear tape. Make sure that your surfaces move freely.
Install the ply control horn for the elevator (the elevator control horn resembles a boomerang and should be installed with the “hook” side down to receive the rubber band tensioning spring).
Install the ply control horns for the ailerons (control horns should extend below the model as the servo is mounted through the underside of the wing).
Cut two lengths of 1/32” music wire to 2-5/8” in length. Bend over plan sheet as indicated starting with the inverted “U”. Make your final bend perpendicular to the plan sheet / building board which will make up the axle for the 1” spindle wheels. Bend a right and left gear leg. Install the landing gear to the gear pockets in the wing
– retain with the 1/16” balsa parts R2A and secure with thin CA. Install the spindle wheels to the gear legs then cut one of the 1/16” aluminum tubes into two 1/8” segments to use as a crush ring for retaining the spindle wheels on the gear legs. Crimp the pieces of aluminum tube to the gear legs and retain with a drop of thin CA
(careful not to glue the wheel to the axle).
Optional: Using the plan sheet as a guide, bend tail skid from 1/32” music wire, insert into tail section and secure with thin CA – Tip: Make your aileron control rods and gear legs first then bend the skid from the remaining scrap 1/32” wire.
Radio Installation
Elevator Servo and Linkage: o Install the 5.4g Sub-Micro elevator servo on the same side as you installed the control horn (A pocket for the elevator servo is provided on either side of the fuselage). Lift servo out of the pocket and place two dabs of hot glue on either side of the servo. Gently press the servo into position – the glue will rise through the screw-mount holes in the servo making a mushroom shaped rivet that does a fine job of retaining the servo. o Install the provided push-rod connector to the INNER most hole on the servo arm. Center the servo arm so that it runs perpendicular to the fuselage. Slide the provided cotter pin into the pushrod connector, leaving 3/16” exposed beyond the connector (the majority of the “eye” side of the pin should extend aft towards the tail section), and secure by tightening the pushrod connector screw. o Take one rubber band and loop it around the dowel on the side opposite the elevator control horn, run it under the fuselage and over the opposing side of the dowel finishing at the hook in the control horn. Use two ¼” lengths of the 1/16” aluminum tube to act as a crush ring to retain the elevator pull line. Cut the provided low stretch monofilament line to run from the servo arm to the top of the elevator control horn (allow for about 3” of excess on either end). Slide both aluminum crush rings into the center of the line. Loop one side of the pull line through the
OUTER most hole in the elevator control horn then back on itself through one of the crush rings.
Slide the crush ring towards the control horn and crimp the ring. Follow the same procedure for the cotter pin side – leveling the elevator and removing slack from the line prior to crimping the crush ring. Further secure the crush ring crimp with a dab of thin CA. o Slide the cotter pin fore and aft in the pushrod connector (DUBRO 845) to adjust the trim of the elevator control surface. Adjust the tension to the control surface by shortening / lengthening the rubber band return spring. You want just enough tension to allow for adequate downward travel of the elevator and to remove the slack or play in the pull line. o Remove excess pull line with a sharp razor blade. The small 1/32” ply doughnut may be used to secure the return spring rubber band to the 1/8” dowel.
Aileron Servo and Linkage: o Install the 5.4g aileron servo to the central pocket in the underside of the wing using the same
Hot Glue attachment method as the elevator servo. o Install two micro push-rod connectors (Dubro 845) on either side of the servo control arm to pick up the aileron control rods. o Make the aileron control rods by cutting two 2-1/2” lengths of 1/32” music wire; make a 1/8” “Z” shaped bend at one end of each wire and Insert the “Z” bend through one of the holes in the ply aileron control horn. Insert the opposite end of the control rod through the micro pushrod connectors in the servo arm. Center the aileron control horn and ailerons then secure the control rods using the set screw in the (Dubro 845) connector.
If you purchased a heat sink for the motor now is the time to install it. Install the motor by keying the end bell of the motor into the F1a former then lever the motor into position at the F1 firewall. Secure the motor

to the firewall with the provided screws. You may hear a snap as the motor end bell slides past the 1/32” ply former. Work the motor into position slowly and do not force the fit .
Connect your ESC to the motor and position it between formers F1a and F2.
Make your radio connections to the receiver and position the battery and receiver within the fuselage to obtain the proper CG balance point. The model should balance 1/8” forward of the main spar.
Flying
Attach the Wing to the fuselage using no more then two rubber bands – two bands crossing in the center provide more then enough tension to retain the wing for racing. Remember to use fresh rubber for each day of flying.
Inspect for and remove any warps from wings / tail surfaces. 3/16” of washout is acceptable and desirable for extra stability. Wash may be heated into the completed wing by slightly lifting the wing 3/16” at the trailing edge and heating the top surface covering with a heat gun.
Center of Gravity - balance the model 1/8” forward of the main spar. Invert the model and place your fingertips between the spar and first turbulator – this is sufficient for balancing the model at the specified location.
Check to ensure that all of your control surfaces operate freely and in the proper directions.
Recommended Throws: o Elevator – 1/8” Up and Down – No more then 3/16” o Ailerons – 1/8” Up and Down o Rudder – (optional) 1/2” Right and Left.
Check the rubber band elevator pull/return spring prior to every flight – replace as required. Make certain that your pull line crimp has been secured with thin CA prior to flying the model.
Make your first flight outside on a calm day. Point the model into the wind, throttle up to full power, take a few steps forward and gently toss / release (don’t throw) the model level into the wind. Allow the model to gently climb to altitude and trim for level flight. Increase or reduce your control surface throws to suit your flying style.
Getting Additional Support
Please contact us at support@stevensaero.com if you have questions or concerns about this product.
4550 Beaumont Rd.
Colorado Springs, CO 80916 www.stevensaero.com