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

the 1/16" ply bottom plate). Align the centerline you drew
on the stab bottom plate with the holes inthe bottom of the
fusechannel and align the trailingedge of the stab withthe
aftedge ofthefusechannel.Make surethatthestab
trailing edge is perpendicular to the fusechannel. Mark the
holes inthe fusechannel onto the stab bottom plate. Drill
1/8" holes atthe marks on the stab.
Mount the Engine & Install
the Fuel Tank
3. Place the fusechannel on the bottom of the stab (on
Note thegraindirection
1.Glue the three die-cut 1/8" plywood firewall formers
Btogetherwithepoxyso the edges accurately align and
the grain directionof the middle formeris90 degrees to the
grain direction of the outer two formers.Wipe away excess
epoxy before itcures.
4. Useepoxy to glue two 4-40 x 5/8" screws inthe holes
inthe bottom of the rear of the fuselage channel. Afterthe
epoxyhas cured,temporarilymountthestabtothe
fuselagechannel and secure it withtwo4-40nuts and
#4 washers.
Note:The bottom of the stab isthe sidewith the 1/16"
plywood stabilizer bottom plate.
2. Test fitthe sandwiched formers inthe front of the
extrudedPVC fuselage. Ifnecessary, sand the edges of
the formersso they fit.
3. Gluethe die-cut 1/8"plywood front firewall former
A,centered,tothethreeformers.Alternatethegrain
direction again. From now on this assembly will bereferred
to asthe firewall.
5. Removematerialfromthebottomof thefinas
needed to accommodate the heads of the screwsinthe
fusechannel that hold the stab on. Temporarily mount the
fin to the fuselage channel with two 4-40 x 1"screws and
4-40 nuts. 4. Fitthe firewall to the frontof the fuselage. Sand the
edges flush with the fuselage sides.
6

5. Cut the spreader bar and other flashing fromthe right
and left Great Planes 40-70 engine mount halves.
6.Drillfour 5/32" holes through the firewallat the four
punch marks infirewallformerA.Use a hammer to lightly
tap four6-32 blind nuts into theholes inthe back of the
firewall.Permanently secure the blindnuts to the firewall
with thin CA.
7.Fasten the engine mount to the firewallwith four
6-32 x 1-1/2" bolts and #6 lock washers and flatwashers.
Donot fully tighten the bolts so you can adjust the engine
mount to fit your engine.
For a sportier appearance, you may side mount your
engine. Just rotate your engine mount (or the firewall) 90
degrees and drill the holes forthe fuellines and throttle
pushrod accordingly. This also locates the muffler below
thefuselagewhich greatlyreduces exhaustresidue
deposited on your model!
secure. Position your engine onthe mount andmark the
location of the mounting holes.
Hint:Sharpen the end of a 1/16" wire rod to a point. Heat
the rod with a lighter anduseitto mark the mounting holes
on the engine mount.
9.Drill four3/32" holes at the marks you made for
mounting your engine with #4 x 3/4" sheet metal screw and
#4 washersincluded withthiskit.Ifyoupreferto mount
your engine with4-40 screws,drill the holes witha #43 (or
3/32") drill. Tap the holes with a 4-40 tap.Use4-40 x 3/4"
screws (not included).
Note: #4 or 4-40 screwsare intended forsportengines
such as the O.S. LA or FP'series. Ifyou are using a more
powerfulengine,use #6 or6-32screwstomountyour
engine. Drill the holes with a 7/64" drill for#6 screws or a
#36 or 7/64"drillfor 6-32 screws.
10.Take the engine mount offthe firewall. Drill a 3/16"
hole throughthe firewallthataligns withthecarburetor
arm. Make sure you don't drill the hole where the engine
mount willbe. Ifthe engine mount will beinthe way,drill
the hole closetotheenginemount to givethethrottle
pushrod the straightest run possible to the carburetor arm.
Drill 15/64" (or 1/4") holes through the firewallforthe fuel
lines. Make sure the holes willnot interferewith the engine
mount.Whenyou'redone,yourfirewallshouldlook
something like the one inthe photo.
8.Slide the engine mount halves inor out to fityour
engine. Tighten the 6-32 bolts so the engine mount is
11. Mark the locations onthe sides, top, andbottom of
the frontof the fuselage forthe firewallmounting holes,
evenly spaced, 1/4"behindthe front edge.Fitthe firewall
7

into the fuselage,making sure the hole forthe throttle
pushrod isinthe correctorientation Tightly tape the firewall
inplace with masking tape Confirm that the locations of the
holes will not interfere with the throttle pushrod Ifthey do,
adjust the locations of those holes Drill holes through the
fuselage and intothe firewall with a 3/32" drill.
12Removethe firewallAssembleyourfueltank
Connect about 8"of fuel line onto the pickup and pressure
fittings on your fueltank Place an approximately 4" x 4"
piece of 1/4" thick R/C foamrubber inthe fuselageas
shown inthe photo so the frontedge isabout 3/4" aft of the
frontedge of the fuse Insert the fueltank into the fuse with
the R/C foam rubber Slide the 12"long,3/16" grey outer
pushrod guidetube into the fuse between the R/C foam
and the fuse so the end will fitinthe hole you drilled in
the firewall
13Fitthe firewallto the fuselage,simultaneously
2Enlarge the middle hole inthepre bent aluminum
landing gear with a 3/16"dnll Place the landing gear on
the bottom ofthefuseand insertan 8 32 x 1/2" socket
head cap screw(fromnow on referredto as cap screw)
intothe middle hole of the landing gear and into the fuse
Drilla 7/64" hole throughthefuselagewheretheouter
holes inthe landing gear align with the line on the bottom
of the fuselage The shaded areas show the location of the
landinggear plates that will beinstalled instep 3.
3Round one corner on the bottom of both landinggear
plates so they fitthe curve inside the fuselage The bottom
of the landinggear plates isthe side with the line you drew.
Place oneof the landinggear plates inside the fuselage so
the lineyou marked isvisible through one of the holes you
drilled inthe bottom of the fuseMark the location of the hole
on the landinggear plate Drill a 7/64" hole through the plate
atthe mark you made Mark and drill the other landinggear
plateinthe other side of the fuse the same way
routing the fuel lines andthe throttle guide tube through the
holes you drilled Temporarily fasten the firewall to the fuse
with eight #4 x 3/8" screws
4Enlarge theoutertwolanding gear holes inthe
fuselageonly witha 5/32"drillbit Use two#6 x 1/2"
screws to mount the landing gear to the fuselage with the
landing gear plates inside You may glue the landing gear
plates to the fuselage with epoxy,butthis isnot necessary.
Mount the Landing Gear
5/32" Wheel Collar
Nylon Steering arm
with 5/32" Wheel
Collar and 6-32 x
1/4"Screw
1Place the fuselage flaton its side so the firewallisoff 5Remove the enginefrom the enginemountSecure the
the end of your workbench Use a 90 triangle or a builder's
square to mark a line across the fronthole in the bottom of
the fuselage Draw a line across the middle of each 1/4"x
5/8" x 3-1/2" plywood landinggearplate.
wire nose gear to the engine mount with two 5/32'wheel
collars andthe nylon steering arm with another wheel collar
as shown inthe sketch Usetwo 6 32 set screws inthe wheel
collars anda 6-32x 1/4" screw inthe nylonsteering arm
8

6.Drill the hub of two 2-1/2" mainwheels with a #19 (or
11/64") drill. Secure each wheel to the landing gear with an
8-32 x 1-1/4"cap screw and two8-32 nuts as shown inthe
photo. Use thread locking compound on the nuts. Mount
the frontwheeltothenose gearwithtwo5/32"wheel
collars. For a finished appearance, cut the excesswire off
the landing gear that protrudesbeyond the wheel collar
(you should dothis on allyour models').
7.Place the fuselageon yourworkbench.Adjustthe
wheel collarson the nose gear so the fuselageislevel.
Secure the 6-32 screws inthewheel collars with a drop of
thread lockorCA.
Optional: Forextrasecurity, fileflat spots on the nose
gearwhere the set screws lock on.
1.Insert three servos into the fuselage channel inthe
orientation shown inthephoto. The front servo(throttle)
should beabout 1/2" fromthe frontof the fuse channel. The
middleservo (rudder) should beas far forward as possible,
yet not concealing the hole forthe frontscrew that holds the
fuse channel to the fuse.The aft servo (elevator) should be
asclose as possible to the rudder servo without touching it.
Securely wrap two layers of 3/4" wide fiber reinforced tape
around the servos and the channel. Install a servo arm on
each servo asshown inthe photo.
2.Temporarily connect the servos to the receiver and
the battery pack. Turn on your radio and center the servo
arms on the servos.Turn offthe transmitterand receiver
anddisconnect the receiver andbattery.
CUTOFF
UNUSED
ARMS
3.Center andglue the 1/2"x 3/4" x 2"balsa blockto the
die-cut1/8"plywood receiver plate.
9

THREADED STUD
1.Thread a nylon clevis onto a 1"threaded stud about
20 fullturns. Thread the other end of the stud about 1/2"
into a 36" innerpushrod tube. Connect the clevis to the
controlhorn on theelevator and slip a 36" greyouter
pushrod guidetube over the inner pushrod tube.6.Trim the 3/16" x 1" x 1-1/4" balsa pushrod spacer
2.Connect another 36" inner pushrod tube and another
36" outer pushrod guide tube to the second fromthe inner
hole on the rudder horn the same as the elevator.
3.Thread one more nylon clevis onto a 1"threaded stud
block so that when you place iton top of your receiver, the
pushrods willalign withtheelevator and rudder servowhen
you run them alongside the block on top of the receiver.
Wraptwoturnsof filamentreinforcedtapearound the
assembly and the fuse channel to hold everything inplace.
and thread the stud into one end of the 48" inner pushrod
tube. Connect the clevis to the second fromthe outer hole
of the rudder horn. Slide a 36" outer pushrod guidetube
over the 48" pushrod tube.
4. Securely tape the outer pushrod tubes to the fuselage
channel about 1"ahead of the stab withfiberreinforced
tape. Make sure the aft end of the tubes donot interfere
withthe cleviseswhen you move the rudder and elevator
to fulldeflection. The short rudder pushrod tube should be
above the long nose wheel steering tube on the rightside
of the fuse channel.
7.Disconnect the clevises fromthe rudder and elevator
horns and slide the pushrods out of the guide tubes. Cut
the rudder and elevator guide tubes about 1-3/4" short of
the elevator andrudder servos. Reinsert the pushrods in
the guide tubes. Cut the pushrods to the correct length and
connectthem to theelevatorand rudder servowithtwo
more 1"threaded studs and nylon clevises.
At this point yourreceivershould besecurely(yetsoftly)
mounted to the fuse channel, your servos should besecurely
mountedto the fuse channel and plugged into your receiver,
your elevator andrudder pushrods should beconnected,and
your fuel tankandfuel linesshouldbeinstalled.
5.Place your receiver and thereceiver plateon the fuse
channelwith1/4"R/Cfoamrubberunder thereceiver.
Connect your on/offswitch, throttle,rudder and elevator
servo cords and anaileron extension cord to your receiver. 8-32 x 1/2" cap screws, #8 washers and 8-32 nuts anda
drop of thread lock.Mountyour engineto the engine mount.
10