DuraPlane DuraStik 40 User manual

Assembly Instructions
Specifications:
Wingspan:
Wing Area:
Fuselage Length:
RadioRequired:
56in(1422mm)
594 sq in(37.9 sqdm)
49 in(1117.6mm)
4-Channel with 4 servos
Weight: 5.5to6 lb(2743g)
EngineRequired:
2-stroke .40to .46engine w/muffler, or
4-stroke .48to.52engine
READ THROUGH THIS INSTRUCTION MANUAL BEFORE STARTING CONSTRUCTION. ITCONTAINS
IMPORTANT INSTRUCTIONSAND WARNINGS CONCERNING THEASSEMBLY AND OPERATION OF
THIS MODEL.
DuraPlane guarantees this kit to befreefromdefects inboth material and workmanship atthe date of purchase.
This warrantydoesnot coverany componentpartsdamagedby use or modification.In no caseshall
DuraPlane's liability exceed the original cost of the purchased kit. DuraPlane reserves the right to change or
modify this warranty without notice.
DuraPlane P.O.Box 788Urbana,IL61803 [phone]
Printed inUSA DURA1140
ENTIRECONTENTS© 1997

Thank you for purchasing the DuraPlane DuraStik 40 The
DuraStik 40 is the thirdgeneration of DuraPlane models
specificallydesignedforaerobaticflightThestick
configuration isreminiscent of the popular Great Planes stik""
series and isa perfect subject fora fastbuilding aerobatic,
fun flying DuraPlane model Because the DuraStik 40 isfully
aerobatic featuring a wing that has nodihedral (and does not
possess the self-righting characteristics found ina trainer), it
isrecommended that you donotattempt to fly the DuraStik
40asyour first model.
Ifthis isyour first model, the best way to learn to flyR/C is
to joina flyingclub The Academy of Model Aeronautics is
thenationalorganizationthatchartersmodelclubs,
sanctions competitions, and insures flyingfieldsacross the
United States We urge you to jointhe AMA Membership
willbringyouflyinginsurance,a subscriptiontoModel
Aviation Magazine, and many other benefits The AMA will
gladly send you membership information and lists of AMA
chartered clubs inyour area where you can seek the help
of experienced modelers.
Academy of ModelAeronautics
5151 East Memorial Drive
Muncie, Indiana 47302-9252
[phone]
FAX [phone]
Web Site:HTTP.//WWW.MODELAIRCRAFT.ORG
Your hobby shop isalso an invaluable place forservice,
partsand informationthatyourequireWe urgeyouto
patronize your local hobby dealer - hes thereto help you
enjoy your hobby.
#11Blades(HCAR0311, 100qty.)
Razor Plane (MASR1510)
Standard and Phillips screwdrivers
Needle nose pliers
Electric drill
Drill Bits 1/16", 3/32", 7/64", 1/8",5/32",
#19 (or 11/64"), 3/16", 15/64" (or 1/4")
X-Acto Building Square (XACR7726)
Kyosho Lexan Curved Scissors (KYOR1010)
Masking Tape
Waxed paper
TopFliteSealing Iron (TOPR2100)
Top Flite "HotSock"(TOPR2175)
Easy-Touch"BarSanders"
Great PlanesC G Machine (GPMR2400)
*A flat,durable, easy to handle sanding toolis a necessity
forbuilding a wellfinished model Great Planes makes a
completerangeof Easy-TouchBar Sanders(patent
pending) and replaceable Easy-Touch Adhesive-Backed
Sandpaper While building the DuraStik, we used a 5-1/2"
BarSander and an11" BarSander equipped with 80-grit
and150-grit Adhesive-backed Sandpaper.
This instruction manualprovides step-by-step instructions for
assembling the DuraStik 40 kit Assembly of the DuraStik 40
consists of six majorsteps,completed inthe following order
BUILDTHETAIL FEATHERS..................................4
ASSEMBLE THE FUSELAGE...................................6
RADIO INSTALLATION ............................................9
BUILD THE WING ...................................................12
COVER THE WING AND TAIL................................15
FINAL ASSEMBLY..................................................17
FLIGHT....................................................................19
Here's the complete listof Easy-Touch BarSanders and
Adhesive BackedSandpaper.
5-1/2" Bar Sander (GPMR6169)
11" BarSander (GPMR6170)
22" Bar Sander (GPMR6172)
33" BarSander (GPMR6174)
44"BarSander (GPMR6176)
Adhesive-backed 12' roll of:
80-grit (GPMR6180)
150-grit (GPMR6183)
180-grit (GPMR6184)
220-grit (GPMR6185)
Assortment pack of 5-1/2" strips (GPMR6189)
We use3M 320-grit wet-or-dry sandpaperfor finish sanding.
2

Fourchannel radio w/4 servos
40 to 46 2-stroke engine w/muffler,or 48 to 52
4-stroke engine
Propellers recommended byyour enginemanufacturer
1Roll EconoKote or Black Baron filmlow-heat
model covering (see Covering, page 16)
Fuel-proof spray paint (see Painting, page16)
(3) 2 1/2" wheels (GPMQ4223)
2-1/4" Spinner (GPMQ4517 - red)
8oz Fuel tank (GPMQ4103)
Medium siliconefueltubing (GPMQ4131)
#64 Rubber bands (HCAQ2030)
1/4" R/C foamrubber sheet (HCAQ1000)
3/4" Wide fiberreinforcedstrapping tape
1/16" Wing seating foam tape (GPMQ4422)
These are additional items you will need to complete your
DuraStikthatarenot included with your kit. Suggested
order numbers are inparentheses
When a specific type of adhesive works best for that step,
we willtellyouwhattypeofglueto use CA dissolves
foam so donotuseiton any part of the wing where it
will contact the foam. Whenever justepoxy isspecified
you may use either 30-minute epoxyor 6-minute epoxy
When 30-minute epoxy isspecified itisrecommended
that you use only 30-minute epoxy because you will need
the working time and/or the additional strength
When you get to each step,read that step completely
through to the endbefore you begin Frequently there is
important information or a note atthe end of the step that you
need to know before you start Photos and sketches are
placedaheadof the step they refer to You can study photos
inthe following steps to get another view of the same parts.
Refer to the Parts Listfora description of the partsand
hardware includedwith the DuraStik 40 kit
Here'sa checklist of supplies you should have on hand
while you'rebuilding We always use Great Planes Pro"
CA and Epoxy.
1oz Medium CA+ (GPMR6008)
1oz Thin CA (GPMR6002)
CA Accelerator (GPMR6035)
CA Applicator Tips (HCAR3780)
30-minute (GPMR6047) or 6-minute epoxy
(GPMR6045)
Pro Wood Glue (GPMR6161)
Pro Threadlocker (GPMR6060)
Lightweight Hobby Filler (White,HCAR3400)
Denatured or IsopropyI Alcohol (to clean upexcess
epoxy)
There are two types of screws used inthis kit:
Sheet metal screws
are designated bya
number and a length.
Forexample #4 x 3/4"
Machine screws are
designated bya
number, threads per
inchanda length. Forexample 4-40 x 3/4"
When you see the term test fit inthe instructions itmeans
thatyoushouldfirstpositiontheparton theassembly
without usingany glueand then slightly modify or custom
fit the partasnecessary for the best fit.
3

bladeto cut the hingeslots inthe centerof the fin TE and
the center of the rudderLEatthe locations you marked.
1.Test fit the shaped1/4"balsa fin front to the shaped
1/4" balsafinrearas shownin the followingphoto.
Ifnecessary, true the joining edges with a barsander and
150-gritsandpaperso thereis no gap betweenthe
two pieces.
2. Glue the fin frontto the finrear with medium CA.
From now on we will callthis assembly the fin. Use your
barsander and 150-grit sandpaper to sand the sides of the
fin flat and even andround the leadingedge.Sandthe fin
smooth with 320-grit sandpaper.
5.Cut three hinges fromthe 2"x 9"CA Hinge Strip
andsnip the corners offas shown inthe sketch. Test fitthe
rudderto the finwiththehinges.Do not glue inthe
hinges until weinstruct you to do so. If necessary,
adjust the hingeslots so the rudderandfin align.
6.While the fin andrudderare stilltemporarily joined
with the hinges, round the trailing edge of the rudder so it
matches the fin.Remove the rudder fromthe fin.Use a
razor plane or sandpaper to shape the leading edge of the
ruddertoa"V".
fin bases to both sidesof thefin. Make surethat the
bottom of the fin andthebottom of the fin basesalign.
Usethis photo for the next foursteps
where shown inthe photo. Usea hobby knife with a #11
3.Usemedium CA to glue the 1/4"x 1/2" x 5-5/8" balsa
CUT HINGE SLOT
WITH HOBBY KNIFE
AND #11 BLADE
4. Mark the locations of the hinges on the rudder and fin
Horn plate
Positionthe horn so
the holes align with
the leading edge.
7.Cut the horn plate off a large nylon control horn.
Position the control horn on the right side of the rudder so
the baseis9/16" fromthe bottom of the rudder, and the
four holes (forthe clevis) align with the LE. Use a ballpoint
pen to mark the location of the two holes inthe base of the
control horn on the rudder and drill two 1/16"holes through
the rudder at themarks.Mount the controlhorn tothe
rudderwith two 2-56 x 1/2" screws and the horn plate.
1.Testfitthe shaped 1/4" balsa stab fronttothe
shaped 1/4" balsa stab rear. Ifnecessary, true the joining
edges with 150-grit sandpaper anda barsander so there is
nogap between the two oieces.
4

2. Gluethe stab front to the stab rear with mediumCA.
From now on wewillcallthisassemblythestab. Use
150-gritsandpaperand a sandingblock toround the
leading edge of the stab and sand the top andbottom flat
andeven. Sandthe stab smooth with 320-grit sandpaper.
7.Mounta control horn to the top of the elevator with two
2-56 x 1/2" screws andthe horn plate.Position the edgeof
the horn base 8-7/16" from the leftedge of the elevator.
3.Draw a vertical centerline onthe center of the stab and
the 1/16" x 1-1/8" x 6"plywood stabilizerbottomplate.
4. Use medium CA to glue the stab bottom plate to the
stab withthecenterlinesaligned. Afterthe CA hardens,
shape the front of the stab bottom plate so itmatches the
front of the stab.
a
1.Inspect the holes inthe aluminum fuselage channel
andremove anyburrsyou find with a metalfile.
5.Mark the locations of the hinges on the stab and 1/4"
shaped balsa elevator as shown inthe photo at step 7.
Cut the hinge slots inthe stab and elevator the same way
you did the finand rudder. Cut fourmore hinges fromthe
CA hinge strip and testfitthe elevator to the stab with the
hinges.Ifnecessary, adjust hingeslots that don't align.
6.While the elevator and stab are still temporarily joined
with the hinges, round the ends and TE of the elevator to
match thestab.Removetheelevatorand use a razor
plane or sandpapertoshape theleading edge ofthe
elevator to a "V".
2. Insert the fininthe aluminum fuselage channel so the
trailing edge aligns with the aft edge of the channel. Mark
the locationof the holes inthebottom and sides of the
fuselage channel onto the fin.Remove the finand drill 1/8"
holes through only the marks on the side of the fin.
5