GRAUPNER STARLET 2400 User manual

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
Modifications reserved. No liability for printing errors 11/2011
1
Order No. 9588
9588.GT33
Instructions
STARLET 2400
For internal-combustion engine up to 33 cc
or
electric motor
This model requires a four-function radio control system

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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2
Specification
Wingspan approx. 2400 mm
Fuselage length excl. spinner approx. 1540 mm
Wing area approx. 76 dm²
Tailplane area approx. 15 dm²
Total surface area approx. 91 dm²
All-up weight according to fittings approx. 9600 g
Longitudinal dihedral 0 - 0.5 degrees
Centre of Gravity approx. 160 - 170 mm aft of the leading edge
Caution: this model is not a toy!
If you are a beginner to this type of powered model, please ask an experienced
model flyer for help and support. If you attempt to operate the aeroplane without
knowing what you are doing, you could easily injure yourself or somebody else.
Please keep your safety and well-being in mind at all times.
Important: before you start construction
Even if you have already built a large number of RC models please read right
through these instructions and check that all the kit components are actually present.
We have taken great trouble to keep construction as simple as possible, without
making any compromises in the area of safety.
Note regarding the film covering
Minor creases or bubbles may develop in the film covering due to major fluctuations
in weather conditions (temperature, humidity etc.); in rare cases you may even find a
slight warp in a component. These minor faults are in the nature of film-covered built-
up wooden structures, and can easily be corrected using a heat gun, as commonly
used for modelling.
Creases: Blow warm air over the area and rub down with a soft cloth.
Wing warp: Hold the panel twisted gently in the opposite direction to the warp,
and apply warm air to remove the creases from the covering.
Caution! do not heat the film more than is absolutely necessary. If the air or the iron
is too hot, the film may melt and holes may be formed.
This aeroplane is highly pre-fabricated and can be built in a very short time. How-
ever, the work which you have to carry out is important and must be done carefully.
The model will only be strong and fly well if you complete your tasks competently - so
please work slowly and accurately.
When self-tapping screws have to be screwed into wood, apply a little white
glue to prevent them shaking loose: just squirt white glue into the hole before
fitting the screw.
Secure all metal screws and nuts with a drop of UHU schraubensicher (thread-
lock fluid) to prevent them working loose.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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Notes on building the model
•Before you start building the aircraft it is essential to study the plan and read right
through the instructions. Please bear in mind the dangers inherent in the handling
of tools.
•When preparing wiring, be sure to use cable capable of carrying the currents likely
to flow when the model is flying.
•Deploy the receiver aerial as far away as possible from high-current cables (at
least 3 cm).
•Remove all traces of grease from the joint surfaces of components which are to be
glued. A good method is to sand lightly before wiping with a non-greasy liquid
detergent solution. The same applies to surfaces which are to be painted,
otherwise the paint will not adhere permanently. Before gluing any GRP parts, and
GRP fuselages in particular, the joint surfaces must be sanded thoroughly with
fine-grit abrasive paper before de-greasing with a solvent such as acetone. This is
the only method of obtaining durable glued joints involving GRP parts.
Additional items required
Glowplug engine / petrol engine and accessories
Recommended internal-combustion engine
Engine
Order No. Capacity cc Silencer Order No. Propeller Order No.
OS MAX FS 200 S
2728 32.4 Included 1318.45.25
Petrol engine GT 33
2772 33 Included 1318.45.25 1318.50.25
Recommended electric motor
Electric motor
Order No. Propeller Order No. Flight battery Order No. Speed controller
Order No.
COMPACT
630
7725
55 x 25 cm
1326.22x10
LiPo V-MAXX 45C
5/4200 18,5 V/4,2 Ah
9740.5
Two required
COMPACT
CONTROL
80 HV
7228
Radio control system
The RC system must feature at least five control functions, with ten servos.
The transmitter should also include a servo reverse facility.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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We particularly recommend: Mx-16 to MC-24 computer systems.
The model is designed for standard-sized servos.
We recommend the following receiver power supply: two GRAUPNER LiFe 2/2900
6.6V JR, Order No. 7672.2; it is important to maintain these batteries carefully before
and after each flying session. We recommend the PRX 5A, Order No. 4136, as ON /
OFF switch.
For connecting the two aileron servos to the receiver you will need two extension
leads, Order No. 3935.65.
Each of the aileron servo leads in the wings needs to be extended using an
extension lead, Order No. 3935.50, while the two elevator servos require extension
leads, Order No. 3935.75.
The receiver and battery should be packed in foam for protection from vibration.
The model is suitable for standard-sized servos with an output torque of around 50
Ncm.
Adhesives
Fast-setting epoxy resin, e.g. UHU plus schnellfest, Order No. 962
Slow-setting epoxy resin, e.g. UHU plus endfest 300, Order No. 950.43
White glue, e.g. UHU Holzleim express, Order No. 958.60
UHU hart, e.g. Order No. 534.35
Cyano-acrylate (“cyano”), e.g. Order No. 5821
Cyano-acrylate, e.g. Order No. 5822
Thread-lock fluid, e.g. Order No. 952
Accessories required to operate the model (not included)
Fuel to suit engine (petrol / oil mixture; see instructions supplied with your engine)
Fuel tubing, e.g. Order No. 1325.2
Manual fuel pump, e.g. Order No. 6870
Ignition battery, Order No. 8716.5
Battery chargers and charge leads for electric-powered version: see the main
FS catalogue
Tools required (not included)
Set of cross-point screwdrivers, pointed-nose pliers, flat-nose pliers, side-cutters,
balsa knife or razor blade, set of twist drills, pencil, felt-tip pen, fine-tip soldering iron.
Assembling the STARLET 2400
The tailplane
Please don’t start assembling the model until you have checked the kit components
and the building instructions, and are familiar with the construction procedure. If you
are not happy with any component, kindly return it to your model shop without delay,
before you have modified it in any way. Remove one arm from the servo output
levers as shown in the photo. Set the servos to centre from the transmitter, then fit
the output levers on the servo output shafts.

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Extend the servo leads using the appropriate extension leads, and ensure that they
cannot slip apart, e.g. by fitting a heat-shrink sleeve or gluing with a drop of cyano.
Connect the servos to the receiver, set them to centre from the transmitter, and fit the
output arms on them.
Fix the servos to the support blocks using the retaining screws supplied with them:
first push the rubber grommets into the servo mounting lugs, followed by the brass
tubular spacers, with the flange on the underside. Fitting the spacers on a suitable
screwdriver first makes them easier to fit. Drill 1.5 mm Ø pilot-holes in the support
blocks, using the metal spacers as a guide, then fit the servo retaining screws as
shown.
The servo leads can now be pulled through the tailplane panels using a length of
thread: tie the thread to the servo lead just behind the connector, then pull it through
until it appears at the root rib.

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Use the tip of a hot soldering iron to remove the covering film over the horn slots, and
glue the horns in them using UHU plus (epoxy).
Apply strips of adhesive tape on both sides of the horn before applying the glue, as
this makes it easy to remove the excess resin while it is still soft.
Place the servo mounts / well covers in the tailplane panels and secure them using
the retaining screws supplied.
Assemble the elevator pushrods, and connect them to the horns and the servo output
arms. Adjust the linkages so that the elevators are at neutral when the servos are
also at centre.
The two tailplane panels are held in place on the fuselage by a sprung yoke and
tapered retainer; glue the tapered pin in the threaded hole in one tailplane root, and
the sprung yoke in the other.

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The two parts are screwed in to the correct depth when the distance between the two
root ribs is the same as the width of the fuselage at the same point. Measure the
distance, then check by plugging in the tailplane panels on the aluminium joiner tube.
The wing
Following the same procedure as described for the tailplane, cut down the servo
output levers, centre the servos, then fit the levers on the servos. Extend the servo
leads using the appropriate extension leads. Install the servos in the servo mounts,
draw the leads through the wings, and fix the servo mounts / well covers in the wings
using the retaining screws provided in the accessory pack.
Use the tip of a hot soldering iron to melt the covering film over the horn slots in the
ailerons, and glue the horns in the slots using UHU plus.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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Apply strips of adhesive tape on both sides of the horn before applying the glue, as
shown in the photo, as this makes it easy to remove the excess resin while it is still
soft. When the glue has set hard, assemble the pushrods as shown in the illustration,
and connect them to the horns and the servo output arms.
With the servo and aileron at neutral, set the pushrod to the correct length and apply
a drop of UHU schraubensicher (thread-lock fluid) to the locknuts to prevent them
working loose.
Use your fingertips to locate the retaining holes for the strut brackets, and melt the
film over them using the tip of a hot soldering iron. Apply thread-lock fluid to the
threaded holes, and screw the bored brackets in as far as they will go.
Fit M3 locknuts on the threaded ends of the wing struts, followed by clevises; connect
the clevises to the brackets in the wings.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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A retaining bolt has to be screwed into each root rib to hold the two wing panels
against the fuselage. Apply thread-lock fluid to the threaded part to prevent them
working loose, and screw the bolts into the sockets as far as they will go.
The fuselage
Drill an 8 mm Ø hole on the inboard side of the wheel spats to accept the wheel
axles; the holes should be positioned about 18 mm above the bottom edge of the
moulding, and in the centre of the wheel opening in the spat. Repeat the procedure
with the plywood doubler, as shown in the photo. Trim the doubler to fit snugly on the
inside of the spat, and glue it in place. When the glue has set hard, extend the hole to
the bottom to form an open slot, filing it to shape, as shown in the right-hand photo.

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Install the undercarriage struts as shown.
The wheel is kept central in the wheel spat opening by means of two collets. Apply
thread-lock fluid to all the screwed joints to prevent them working loose.
Locate the undercarriage screw-holes in the bottom of the fuselage with your finger-
tips, and remove the covering film over them using the tip of a hot soldering iron.
At this point the two undercarriage legs, the tension spring bracket and the wing strut
brackets can all be screwed to the underside of the fuselage.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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Connect the two tension springs as shown in the photo.
Use your fingertips to locate the slots in the rudder for the horn, and melt the film
over them using the tip of a hot soldering iron. Glue the GRP horn in the rudder,
taking care to centre it, i.e. it should project by an equal length on both sides.
Attach the rudder to the fuselage by slipping the pivot rod through the hinge lugs.
Attach the tailwheel unit to the underside of the fuselage using the two socket-head
cap screws supplied.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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Install the pull-cable rudder steering linkage as shown in the photo. The two tension
springs cause the tailwheel to follow the movements of the rudder.
Press the rubber grommets and tubular metal spacers into the mounting lugs of the
rudder servo, as described at the start of the instructions, and mount the servo in the
servo plate. Connect the pull-cables to the servo output arm, and adjust the clevises
on the threaded couplers to place the steel cables under light tension.
The next step is to install the cabane on the fuselage: use your fingertips to locate
the openings and holes in the fuselage turtle deck, and remove the covering film over
them using the tip of a hot soldering iron. Mount the cabane on the fuselage as
shown in the photos below.

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Apply UHU schraubensicher (thread-lock fluid) to all the screwed joints to prevent
them working loose.
The wing centre section can now be screwed to the cabane.
Locate the holes in the top of the wing centre section for the wing retaining screws,
and remove the film over them with a hot soldering iron.
The fueltank
Start by completing the stopper assembly, as shown in the photo below; take care to
cut the fuel line to the clunk pick-up to the correct length: it must be able to move
freely inside the tank when the stopper is in place, without binding or jamming.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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The other two tubes - filler and overflow - must be extended with pieces of fuel tubing
so that the one rests at the bottom of the tank, the other at the top against one side.
Now mark the three fuel lines with a felt-tip pen to identify them (carburettor, filler,
pressure line / overflow). Push the stopper over the throat of the tank and tighten the
cross-point screw to clamp it in place. It is essential to tighten the screw to the point
where the tank is completely sealed.
The completed fueltank can now be fitted inside the fuselage, routing the fuel lines
through the hole in the firewall. Glue the two formers in the fuselage to prevent the
tank shifting, as shown in the photo.

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The fuselage should be set up on the undercarriage before the engine is installed, as
shown in the pictures. Fix the petrol engine to the firewall using the socket-head cap
screws and aluminium spacer pillars provided.
Install the throttle servo in the servo plate as shown in the photo. Fit a swivel pushrod
connector in the servo output arm (lever length approx. 13 mm), checking that the
connector rotates smoothly, without lost motion.
Fix the throttle servo in the servo plate using the retaining screws supplied with the
servo. Connect the Z-bend of the throttle pushrod to the carburettor throttle arm. Set
the carburettor to ‘half-open’ and the servo to centre, then clamp the pushrod in the
swivel connector by tightening the grubscrew.
The ignition unit should be mounted on the firewall just behind the silencer.
Before the cowl can be installed the appropriate clearance openings must be cut and
filed to shape for the silencer, cylinder head, etc.

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The cowl is fixed to the fuselage using three screws: place the cowl on the fuselage
and position it so that there is an even gap about 1.5 mm wide between the front of
the cowl and the spinner backplate. Now mark the trailing edge of the cowl on the
fuselage at right, left and top. Drill pilot-holes for the cowl retaining screws, positioned
so that they engage in the centre of the thickness of the firewall.
The propeller and spinner can now be installed. Check before each flight that these
parts are properly tightened and secure.
Installing the electric motor
The electric motor is mounted on the firewall using the bulkhead, screws, nuts and
cylindrical aluminium spacer pillars supplied in the kit.
Mark the position of the motor retaining screws on the motor bulkhead, and drill the
holes to suit the screws you are using.
Mount the electric motor on the motor bulkhead.

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The motor assembly can now be mounted on the firewall, as shown in the photo.
For the electric version no additional openings are required in the cowl. The moulding
is fixed to the fuselage as described earlier for the petrol-engined version.
The flight batteries are installed in the fuselage using the battery tray provided: the
tray’s front locating lug fits in the slot in the firewall, and at the rear it is secured by a
plastic screw. Shorten the plastic screw as shown in the picture.

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The two flight batteries can be attached to the battery plate using cable-ties.
The receiver batteries should be installed in the fuselage under the flight batteries,
and must be secured properly to prevent them shifting in flight.
When the model is flying, the speed controller simply rests on top of the two flight
batteries. Slide the battery tray into the fuselage from the cockpit opening, engage
the front locating lug in the slot in the firewall, then tighten the plastic screw to
prevent it shifting in flight.
The receiver can be attached to the servo plate using Velcro (hook-and-loop) tape.
Deploy the servo leads under the servo plate, and up to the receiver’s socket row.

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Install the PRX 5A ON / OFF switch in either the right-hand or left-hand fuselage
side.
The windscreen is fixed to the cockpit cover using small screws, as shown in the
photo below. The front edge should be sealed using a strip of clear adhesive tape.
The dummy pilot can now be glued in the cockpit using Stabilit Express.
Assembling the STARLET 2400
It is advisable to connect two extension leads, Order No. 3935.65, to receiver output
sockets 2 and 5 permanently, as this makes it easier to connect the aileron servo
leads from the wings when the model is rigged. Run the fixed extension leads up the
cabane, and fix them to the struts with adhesive tape. They should exit the openings
in the root ribs of the wing centre section. Fit the joiner tube through the centre
section and slide the outboard wing panels onto it. Plug the two aileron servos into
the extension leads in the centre section, then push the wings up against the centre
section, and rotate the retainers to fix the panels in place.

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Slide the two tailplane panels onto the aluminium joiner tube and push them up to the
fuselage. Connect the extension leads, then push the panels in until the tapered
retainer engages in the yoke.
Balancing the STARLET 2400
With the fueltank empty, or the flight packs in place, support the model under the
wing roots adjacent to the cabane at a point about 160 - 170 mm aft of the root
leading edge. If the Centre of Gravity is correct, the model will now balance level,
ideally with the nose angled slightly down. If necessary, adjust the position of the
receiver bat-teries until the CG is at the stated point. Before flying the aircraft, set the
transmitter trims to centre and ensure that the control surfaces are also exactly at
neutral.
Control surface travels
Ailerons 25 mm up, 9 mm down
Elevators 20 mm up, 20 mm down
Rudder 35 mm to right and left
We recommend setting 30% Exponential on all control surfaces at the transmitter.
Important:
When fitting and adjusting the various linkages you should ensure that they move
freely, without binding, are able to move to their full extent - including trim travel - and
are not obstructed mechanically at any point.
When you move the rudder stick to the right, the rudder should also deflect to the
right (left stick: left rudder). Pull the elevator stick back towards you, and both
elevators must deflect up (stick forward: elevator down). If you move the aileron stick
to the right, the right aileron should rise, the left aileron fall. When you move the
throttle stick forward, the engine (or electric motor) should run at full power; pull the
throttle stick back, and the engine should idle (or stop). We recommend assigning the
landing flaps to a three-position switch.
Now all that remains is for us to wish you many hours of fun and pleasure flying your
STARLET 2400.
Yours - the team !