Hobbico avistar 40 User manual

EntireContents © Copyright, 1995
HCAZ3005V 1.0

KNOW YOUR MODEL'S PARTS.
Takea momentnowto
matchtheboxcontents
with the items listed here.
FollowingtheAvistar
assemblyinstructions
willbe quiteeasy ifyou
identifyandorganizethe
partsbeforeyoubegin.
Engine Mounting Parts
Part# Quantity
3mm nuts............................................4
3x 25mmmachinescrew...................4
3mm washers......................................4
Pushrods..............................................2
3mmlockwashers..............................4
Pushrodguidetubes...........................2
46
25
26
28
43
.53
Wing Assembly
Part# Quantity
includedatthe back
thismanual.
Rightwingwithaileron.............................1
Leftwingwithaileron............................... 1
Plywoodwingjoiners................................3
Wingcentertape.......................................1
Aileronservo tray......................................1
Aileronservotraymountingblocks.........2
Aileroncontrolhorns................................2
Threadedaileronpushrods......................2
Clevises......................................................2
Clearclevis retainingtube........................1
Wingalignmentpackage..........................1
35
Please take yourtimeand read throughtheinstruction
manualbeforestartingtobuildyournewairplane.If
you have anyquestions,please feel free to give usa call
at(217)398-8970.We hopeyouenjoybuildingand
flyingtheAvistar.
Replacement Parts Available
HCAA3020 WingKit
HCAA3021 FuselageKit
HCAA3024 Wing Tip Set
HCAA3022 TailSet
HCAA3023 LandingGear Set
25
28
23
19
21
2
-hankyou forpurchasingtheHobbicoAvistarARF! Thisall
wood sport/trainercan be readyto flyina fractionof thetime
itwouldtaketo builda conventionalwood kit.Itfeaturesa
semi-symmetricalairfoilfora good combinationof acrobatic
performanceandstability.Withthehelpof a competent
instructor,learningto flytheAvistariseasyandenjoyable.For
thesportpilot,theacrobaticcapabilitiesare farsuperiorto
basic trainerswithflat-bottomwings.
Horizontalstabandelevator.........I
Verticalfinandrudder...................1
Clevises...........................................2
Controlhorns.................................2
Clearretainingtube....................... 1
Pushrods.........................................2
2x 15mmmachinescrews ............4
DorsalFin.......................................1
Dorsal FinDecal.............................1
Tail Assembly
Part# Quantity

3
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Metric Scale
InchScale
0" 1" 2" 3" 4" 5" 6"
Fuselage................................. 1
Wingmountingdowels.........2
Servo tray...............................1
Plywood stabbase.................1
Spinner...................................1
Servo traysupport.................1
Part#
Quantity
17
18
14
13
15
16
33
Fuel Tank & Parts
Part#
Fueltank..............................................1
Rubbertankstopper...........................1
Fuelpick-upweight(clunk)...............1
Plasticstopperdisks
(one large andone small) ...................2
Aluminumfueltubing
(oneshortandtwolong)....................3
3x 18mm sheetmetalscrew ..............1
Silicone Fuel line..................................1
Foam tankcollar.................................1
Quantity
*Sketches shown are not
actualsize or to scale.
47
29
27
32
Landing Gear
Part# Quantity
Main landing gearstruts ...........2
Nose gear strut ...........................1
PlasticSteeringArm...................1
Landinggearstraps ...................2
Wheels........................................2
Wheelcollarsw/set screws ......4
3x 10mm sheet metalscrews ...4
Pushrod connector ....................2

Glues
Choosea highquality6-minutcand30-minuteepoxy,such
as GreatPlanesProEpoxy,whichhasbeenformulated
especiallyforR/Cmodelbuilding.ProEpoxiesoffera strong
bondanda varietyof curingtimessuitedforevery stepof
assembly.You'llalsoneeda thin,instant-settingCA
(cyanoacrylate),a thickerCA+,plusrubbingalcoholforeasy
epoxycleanup.
Hardware
Toolsandaccessoriesrequiredforassembly
includea hobbyknife,smallandlargePhillips
screwdrivers, needle nose pliers, drill with
1/16",1/8",11/64",5/64",3/32"and5/32"bits,
ruler,#64 rubberbands,1 footof mediumfuel
tubing,andpetroleumjelly.
Model Engine
PoweryourAvistarwithanyhigh-quality,
.40-sizemodelengine.TheO.S..40FPor
Super Tigre GS-40 are fine engines for this plane.
Lookforfeaturessuchas easy break-in,easy
starting,efficientcarburetionandlow
maintenance.Checkthemanufacturer's
recommendationsforpropellerstousewith
yourengine.
Radio Equipment
To controlyourAvistar's"flightpath,"you'llneeda 1991
legal4-channelaircraftradiosystemwithtourstandard
servos. Many4-channelradiosincludejustthree.Youmay
need topurchasethefourthseparately,HobbicoCommand
servos are available singularly and will workgreatforthis
plane.'1 heservos,batterypack,andradioreceiverwillhe
mountedon-boardvourmodelandneedtobe cushioned
from jolts and vibration. I Half-inch thick foamrubber sheets
(BCAQ1050)areavailableforthispurpose.
Getting Ready for Flight
YourHobbicoAvistarcanbereadyfortakeoffinaslittleas20 hours.Your
hobbvdealerorflyinginstructor(seenextpage)canhelpyoudecidewhat
accessoriesyou'llneed forflight.Mostareone-time-onlypurchases- likea
glowplugigniter(see glossary),fuelpump,and"chickenstick"orelectric
starter. You will also need toobtainmodelglow fuel. Useglowfuelwith a 10-
15% nitrocontentto keep yourengineperformingatitspeak.
Other General Items Required
EpoxyBrushes(GPMR8062)
Foam Kubber(HCAQ1050)
FeltlipPen
MaskingTape
Z-Bendpliers (Optional)
WireCutter
MixingSticks(GPMR8055)
PhillipsScrewdriver
SandingBlockw/150gritpaper
MediumFuelTubing(GPMQ4131)
RubbingAlcohol
Clothespins
String
AdjustableWrench
PaperI towels
"1"Pins
4

Ifyou'rea beginner,thebest way
to beginflyingyourAvistaris with
anexperiencedR/Cpilotorflying
instructoratyourside.You'lllearn
faster,andavoidriskingyour
modelbeforeyou'retrulyready
to solo.
Where do youfindaninstructor?
Askatyourlocalhobbyshop.
They'llhaveinformationabout
flyingclubsinyourareawhose
membershipincludesqualified
instructors.Youshouldalsojoin
theAcademyof ModelAeronautics
(AMA), a 165,000 member-strong
nationalorganizationwith
morethan2,300chartered
clubsacrossthecountry.
Throughanyoneofthem,
instructortrainingprograms
areavailable.ContacttheAMA
attheaddressorphone
numberbelow:
Academy of Model Aeronautics
5151 EastMemorialDrive
Muncie,IN47302-9252
[phone]
JOIN THEAMA
Before you fly:
1.Makesurethatnootherfliersareusingyour
radio frequency.
2.Yourradiotransmittermustbe the FIRST thingyou
turnON,andtheLAST thingyou turnOFF.
3.Doublecheck allcontrolsurfaces,makingsure they
aresecure andmove intheproperdirection.
4.Make surethatthe transmitter& receiver batteries are
fullycharged.
Fuel storage and care:
1. Do notsmokenearyourengine
or fuel.
2.Store allenginefuelina safe, cool, dry place, away
fromchildrenandpets.Modelfuelwillevaporate,
so makesurethatyoualwaysstoreitwiththe
cap secure.
When starting and running your engine:
1.Alwayswearsafetyglasses.
2. Makecertainthatyourglowplugclipis securely
attachedtotheglowplugandcannotpopoff,
possiblyfallingintothespinningpropeller.
3.Use a "chickenstick"or electricstarterto start the
engine- NOT yourfingers.
4. Makesurethatthewiresfromyourstarterand
glowplugclipcannotbecometangledwiththe
spinningpropeller.
5.Do notstandatthesideof thepropellerwhen you
startorruntheengine.Evenatidlespeed,the
spinningpropellerwillbe nearlyinvisible.
6.Ifanyengineadjustmentsare necessary, approach
theengineonly from behind thespinningpropeller.
90-Day Limited Warranty
IIyou.1astheoriginalownerofthismodel, discover a defect inparts
or workmanshipwithin90daysofpurchase. Hobbicowillrepairor replace
it - .11 the option of our authorised U.S. repair facility, Hobby
Services withoutcharge. Our liability does not includecostof shipping to
us. I however, Hobby Services will pay shipping expenses to return your
modeltoyou.
You mustprovideproof ofpurchase,such as your original purchase
invoice or receipt,toryour model's warrantytohehonored.
TIhis warrantydoes notapply todamage or defectscausedby misuse or
improper assembly,serviceor shipment.Modifications,alterationsor
repair by anyone otherthanI Hobby Services voids thiswarranty.We are
sorry,but wecannotheresponsiblefor crash damage and/orresulting
loss ofkits.engines, a cessories. etc.
Repair Service
YourAvistarmusthereturneddirectlyto1 Hobby Services for warranty
work.1headdressis:
HobbyServices.Ann:ServiceDepartment,16) InterstateDrive,
Champaign.11. (61821-1067Phone:[phone].or forproduct
information and technicalsupport please contact us at(217)398-8970
Please follow theinstructionsbelow whenreturningyour model. I his
will help our experienced technicians to repair and return it as quickly
aspossible.
1. ALWAYS return your entire system, including airplane and radio.
2. Disconnect thereceiver batteryswitchharness and make surethatthe
transmitteristurnedoff.Disconnectall batteriesanddrainall fuel.
3. Includea listofallitemsrelumedanda THROUGHwritten
explanationoftheproblem and serviceneeded. IIyouexpectthe
repairtobe coveredunder warranty,alsoincludeyourproof
of purchase.
4. Includeyour full returnaddress and a phone number where you can
bereachedduringtheday.
If your model is [past the 90-day warranty period or is excluded from
warrantycoverage, yon canstillreceiverepairserviceIhroughHobby
Servicesata nominal cost.Repaircharges and postagemay be prepaid or
billed COD. Additionalpostagechargeswillbeappliedlor non-warranty
returns.Allrepairsshipped outside theUnited Stalesmust beprepaid in
U.S.fundsonly.
Allpictures,descriptions and specifications found inthis instruction
manualand on the product packagearesubjecttochangewithout notice.
5

Special Note:
You shouldchargeyourradiosystem beforestarting
to build.Followingthemanufacturer'sdirections,
connectyourtransmitterandreceiverbatteriesto the
system'scharger.Thiswaytheradiowillbe ready
when it istimeto install and test the components.
both sides of one of the wing joiners.Sandwichthis
coatedjoinerbetween theremainingtwo.Quickly
proceed throughthefollowingsteps (3and4)before
theglue cures.
1. Locatethe1/8"(3mm)die-cutplywood wing
joiners.Arrangethethree"V-shapedjoinersinthe
same orientationas theywillbe gluedtogether.Sand
offany bumps from the edges.
Remove the excess epoxy
LJ3.Excessepoxywillsqueezeoutof theseams
between thejoinersandmustbe removed before the
epoxy is allowedtocure. Use a paper towel to remove
the excess epoxy.
Glue the wing joiners
Note: Please read steps2 through4 beforegluing.
Q2. Mixapproximately1/4oz. (7.5ml)of30-minute
epoxy usinga mixingstick and a cup.Usinga mixing
stick or epoxy brush, apply an even coat of epoxyon
Clamp the wing joiner
Q4. Use clothespinstoclampthewingjoinersfirmly
together.Ifanymoreepoxysqueezesout,remove
usinga papertowel.Make sure thejoinersare evenly
linedupwitheachother,setthisasideuntil
fullycured.
6

Mark the centerline on the joiner Trial fit the wing joiner
5.Aftertheepoxy has cured andthe clothespins
havebeenremoved,drawa centerlineonboth
sidesof theplywoodwingjoinersandthetwo balsa
5/16"squarex 1-7/16"(8mmsquarex36mm)aileron
servo traymountingblocks. Use theplywood joiner
as a templatetomarkthewingdihedralangleonboth
of thebalsaaileronservo traymountingblocks.Put
thebalsa blocksaside foruse in latersteps.
Even the edges
1-16.Usinga flatsandingblockorsimilartool,sand
thewingrootsso theywillseat togetherwithno gaps.
Do notsandtoomuchorthedihedralangle
could change.
Mark the wing cavity
Q7. Marktheaileronservo locationon bothwing
panelsusinga felttippen.Usinga hobbyknife,cutan
openingintothepanelsfollowingthelinesyou
justdrew.
Q8.Trial Fit thewingjoinerinboth wingpanelsby
slidingthejoinerintothejoinercavityinthewing.
Thejoinershouldslideinwithlittleresistanceupto
thecenterline.Also trialfitthe3.6mm x4mmx 25mm
wing alignment peg intotheholes at thetrailingedge.
Ifthewingjoinerwillnotfitinthecavity,lightlysand
anyexcess epoxy or unevensurfacesfromthejoiner
edges, sides andends. Caution: A snug fitis desirable
betweenthejoinerandthewingcavity.Do not
sandexcessively.
Viewing the wing dihedral
Q9.Pay close attentionto theorientationofthewing
joinerinrelationtothewingpanel,creatingthe
dihedralangleas shown.Trialfitthewingpanels
together.They should Fit flushagainst each otherwith
no gaps.
NOTE: When performingthefollowingsteps, be sure
tousea sufficientamountofepoxytoforma
completeandsolidbondbetween theplywood wing
joinerandthetwowinghalves.Thisis themost
importantgluejointtheentireairplane.
7

Please read through the following three steps before
mixing any epoxy. You must complete these steps
within 20 minutesfrom the timeyou mix the epoxy.
Glue the joiner
outsideof thewingusinga papertoweldampened
withrubbingalcohol.Use several stripsof masking
tapeonbothsidestoholdthewinghalvestightly
together. Let theepoxy fullycure.
Q10.Mixl/2oz.(15ml)of30-minuteepoxy.Usea
mixing stick or epoxy brushtoapplyepoxy toallfour
sides ofthejoinercavitywall.Insertthejoinerintothe
cavityuptothecenterlinemarkedon thejoinerplate.
Be sureyouareinstallingthejoinercorrectly. Quickly
proceed to the next step.
Apply epoxy to the wing root rib
Q11.Applyepoxyinsidethejoinercavityofthe
remainingwingpanel.Next,coat thewingroot ribs
on bothpanels.Insertthewingalignmentpeg into
theholeatthetrailingedge. Quicklyproceed tothe
nextstep.
Join the wing halves
-I12. Assemblethetwowinghalveswiththetightest
seam possible.No gaps shouldbe showingbetween
the two wing halves. Clean anyexcessepoxy fromthe
Trim the covering
Q13.Holdtheplywood aileronservo trayover the
hole inthebottomof thewing.Trace theoutsideof
thetraywitha felttippen andthenremovethetray
fromthewing.Drawtwolines5/16"fromtheends
as shown.Carefullyremove onlythecoveringwithin
thelinesusinga new #11bladeina hobbyknife,
beingcarefulnottocutintothebalsa
wingsheeting.
Shape the mounting blocks
Q14.Locatethetwo balsaservo traymounting
blocks (markedearlierinstep#5 page 7) andposition
themwiththemarkeddihedrallineup.Cutor sand
themarkedangleoutof theblock.Thisangledside
willbe placedagainstthewingwhentheservo tray
isinstalled.
8

Assemble the servo tray
15.Gluethebalsaaileronservo blocksontothe
servo traysothattheangled side you justcutisfacing
away fromtheplywood tray.
Trial fitting the aileron servo
Q16.Trial fittheaileronservo intotheservo trayand
theholeinthebottomofthewing.Enlargeeither
hole, if needed, witha hobbyknifeor a fine-toothed
fileuntila properfitisachieved.Theplywoodtray
shouldnotactuallycontacttheservo. Leave a 1/64"
gap allthewayaround.Remove theservo.
Install the servo tray
—J 17. Mixl/8oz.(3.5ml)of6-minuteepoxytoglue
theservo traytothebottomsideof thewing.Apply
equalamountsof epoxyto themountingblockson
bothendsof theservo tray.Attachtheservo trayto
thebottomof thewingwiththeservo wireharness
notchfacingtheleadingedge of thewing.Allowthe
epoxytofullycurebeforeproceedingtothenextstep.
Apply the center tape
Q18.Startingatthefrontof theaileronservo tray,
applythe1/2"(12.5mm)whitewingcentertape
completelyaroundthewingover thejoint.A small
amountof pressureshouldbe appliedto makea
smoothseam.
Check the aileron hinge
D19.Gentlytugon each of theaileronsateach hinge
location.Ifanyof thehingesare loose, regluethemas
describedhere.First,flexthesurfacealltheway one
direction(DO NOT REMOVETHEAILERON).Apply5
dropsof thinCA ontoeach hinge.Use a papertowel
toabsorbanyexcess glue.Waita few minutesforthe
gluetoharden,thenflexthesurfacetheother
directionandgluetheotherside of thehinges
inthesamemanner.Finally,flexback
andforthseveral times to free up
theaileron.
9

Install the aileron control horns Securing the aileron pushrods
_120.Thread(heaileroncontrolhornsontothe
torquerodsuntilthereis 3/4"(19mm)of torquerod
between thewingandcontrolhorns.
1-123.Locatethe1/4"(6.5mm)diameterclear
retainingtubeandcuttwo 1/4"(6.5mm)pieces. Slide
onepieceontoeachclevistosecure the connection
between theclevis and thehorn.
Assemble the pushrods
Thisconcludesthewingassemblyfornow. Tape the
pushrodstothewing to keep themin place untilyou
installtheservo.
Q21. Locatetwoplasticclevises and two 8"(203mm)
aileronpushrods.Threadtheclevisesontothe
threadedend of thepushrodsuntiltherod begins to
protrudeinsideof theclevis between theforks.
Install the pushrods
Q22. Attachthepushrodstotheaileroncontrol
horns.Press theforksof theclevistogether untilthey
snapintoplace.
10

Locate the wing dowel holes
1.Locate thefourroundholes,twooneachsideof
the fuselage, andremove thecoveringover each hole.
Caution: Do not cut out the rectangular holes in the
sideofthefuselage.
Locate the stabilizer slot
Q3.Locatethehorizontalstabilizerslotunderthe
coveringon thetailsectionofthefuselageby pressing
lightlywithyourfinger.The slotis locatedon both
sidesofthetail.Usinga hobbyknife,carefullyremove
thecovering,exposingtheslots.NOTE: Do not cut
into the wood around the slot.
Install the plywood stabilizer mount
Install the wing dowels
D2.Insertbothwingmountingdowelsso they
protrudeanequalamounton bothsides. Mix1/4oz.
of 30-minuteepoxy.Applygluearoundthedowels
next to thefuselage androtatethemin and outto help
forcetheglueintotheholes.Usinga papertowel,
spread theexcess gluearoundtheendsof thedowels.
Thiswillfuelproofandaddstrengthtothewood.
Fromtheinsideof thefuselage,applymoreepoxy
aroundthedowels wheretheymeet thesides. These
wingdowels will be used as anchors for rubber bands
to hold the winginplace.
LJ4.Locatethe1/8"(3mm)plywoodstabilizer
mountingbase andtrialfititintothebottomof the
horizontalstabilizerslot.Lightlysandthebase if
necessary to obtaina good fit.Remove thebase from
the fuselage.
Glue the mount in place
Q5.Mix1/8oz.(3.5ml)of 30-minuteepoxy. Usinga
mixingstick,applya generousamountofglueintothe
slot andpositionthestabilizermountingbase firmly
inposition.Removeanyexcess epoxy thatremainson
thetopof thestabilizerbase andon theoutsideof
the fuselage.
11

Remove the tail post
themas describedhere: First,flexthesurfaceall the
way onedirection(DO NOT REMOVETHESURFACE).
Apply5 dropsof thinCA ontoeach hinge.Use a paper
toweltoabsorbtheexcess glue. Waita few minutesfor
thegluetoharden,thenflexthesurfacetheother
directionandgluetheotherside
ofthehinges.Finally,flexthe
surfacebackandforthseveral
times to free itup.
6.Locatedattherearof thefuselage,behindthe
horizontalstabilizerslot,arethebalsatailposts.These
postswereleftformanufacturingalignment.The
postsmustberemovedinordertoinsertthe
horizontalstabilizer.Usinga sharphobbyknifeor
razor saw, cut theposts even with the slot asshown in
the picture.
Locate the vertical fin slot
CJ7.Usingyourfinger,locatethevertical finslot on
thetopof thefuselage.Remove thecovering witha
hobbyknife.
Check the rudder and elevator hinges
Q8.Gentlytugon therudderandelevatorateach
hinge location.Ifanyof thehingesare loose, reglue
Mark the centerline
-J9. On thetopsurfaceof thehorizontalstabilizer,
measuretofindtheexactcenterfromsidetoside.
Draw a "centerline"usinga felt-tippen.Next,extend
thatlineontothetrailingedge,inthehingegap, as
shown.(DONOT MARKONTHEELEVATOR.)
Align the stabilizer with the wing
A=A
B=B
A A
B
B
Q10. Insertthestabilizerintothehorizontal
stabilizerslot soitis centeredinthefuselage (A).Place
thewingontothefuselageandviewtheplanefrom
therear.Thestabilizershouldbe parallelwiththe
wing(B).Ifnot,sandthestabilizermountingplatea
littleat a time untilcorrect.
12

Align the stabilizer with the fuse
T-PIN
STRING
STRING
EQUALMEASUREMENTS
drawninthelast step.Next,carefullycutthroughthe
coveringusinga new#11knifebladeattheinside
linesandremovethecoveringfromthecenter.Do not
cutthewoodunderthecovering!Thiswould
seriouslyweakenthestabilizerandcouldeasily
cause thestabilizerto breakinflight.Ifthestab
breakstheplanemay crash, sobe very carefulwhen
you makethiscut.
11.Attacha pieceof stringwitha T-pintothe
centerof thefuselageas shown.Holdthestringtothe
cornerof thehorizontalstabilizer.The distancefrom
thepintothehorizontalstabilizermustbe exactly the
sameon bothsides.
Mark the stabilizer location
Q12.Withthestabilizerproperlyaligned,usinga felt
tippen,tracea linearoundthetailof theairplaneon
thetopandbottomof thehorizontalstabilizer.
Remove the center covering
LJ13.Removethestabilizeranddrawtwoadditional
lines,on thetopandbottom,1/16"inside thelines
Install the stabilizer
—114. Mix1/4oz.(7.5ml)of30-minuteepoxy. Usinga
mixingstick,placeglueinsidethehorizontalstabilizer
sloton allsidesincludingthehorizontalstabilizer
mount.Insertthestabilizerfromtherear,andadjust
thealignment.Wipeoffanyepoxythatsqueezes out
usinga papertoweldampenedwithrubbingalcohol.
Re-checkthe alignment.Then,takea breakuntilthe
glue cures.
Install the vertical fin
U15.Trialfitthefinintotheslotinthetopofthe
fuselage.Sandtheedges ifnecessaryfora snugfit.
Mix1/4oz.(7.5ml)of30-minuteepoxy.Usinga
mixingstick,applyepoxy to thetopof thehorizontal
stabilizerthroughtheslot.Applyepoxytothesides
andbottomsurfacesof thefinbasethathavebalsa
wood exposed. InserttheFin intotheslot,makingsure
thefinbaseisseatedfirmlyonthehorizontal
stabilizer.Checkfora perpendicularangle between
thefin and the
stabilizerwhen
viewingfromthe
rear.Checkthis
alignmentseveral
timesasthe
epoxy cures.
90
90°
13

Apply the decaf to the dorsal fin Attaching the rudder control horn
Q16.Attachthewhitedecal tothebalsa dorsal finby
wrappingitaroundthetop.Trimoff theexcess decal
materialeven withtheedges.Do not apply to the flat
bottomor aftedges
Install the dorsal fin
Q17.Holdthedorsalfininpositioninfrontof the
verticalfin.Usea rulerto measureandpositionthe
fronttipofthefininthecenterof thefuselage.
Usinga smallamountof6-minuteepoxy,carefully
gluethedorsaltinontothefuselage and to thevertical
fin,makingsure it is centered properly.
Locations of the control horns
Q18.Noticethelocationsandalignmentof the
controlhornsinthisphotomarkinganddrilling.The
ruddercontrolhornmustbeontheleftside.The
elevator hornmustheunderneath
andon therightside.The control
hornsshouldbepositionedso
theholesarelinedupwiththe
hingeline. (Seesketch)
1-119.Positiona controlhornasshowninthe
previoussketch,7/8"(22 mm)fromthebottomof the
rudder.Markthetwoholeswitha felttippen. Angle
thehorn slightly soit isstraight with the fuselage.
Attach the control horn
Q20. Drilltwo3/32"(2.4mm)holesstraightthrough
thebalsarudderatthemarks.Place a dropof thinCA
intoeachhole.Thiswilladdstrengthtothebalsa.
Redrilltheholes to remove anyexcess glue.Inserttwo
2x 20mmmachinescrews throughthecontrolhorn,
andrudder,thenfinallyscrewingthemintothe
controlhornbackplateon theoppositesideof the
rudder.Tightenthescrews butdo notcrushthebalsa.
Cutofftheexcess threadsthatstickoutusinga
wire cutter.
Install the elevator horn
Q21.Attachtheelevatorcontrolhorninthesame
manneras therudder.Place thecontrolhornon the
bottomof theelevator7/8"(22mm)awayfromthe
fuselage(see previousphotoatstep18). Markthetwo
holes witha felttippen. Drilltwo 3/32"(1.6mm)holes
straightthroughthebalsa elevatoratthemarks.Place
adropof thinCA intoeach hole.Redrilltheholes to
removeanyexcessglue.Threadtwo2 x 20mm
machinescrews throughthecontrolhorn,elevator
andfinallyintothecontrolhornbackplateon the
oppositeside. Tightenthescrews butdo not crush the
balsa. Cut off theexcess threads.
HingeLine
14

Cut the rudder pushrod exit Prepare the channel for the gear
22. The pre-cutrudderpushrodexitholeis located
on topof thefuselageon thesame sideas therudder
controlhorn.Usinga hobbyknife,removethe
coveringfromtherudderpushrodexithole.
Cut the elevator exit
D23.The pre-cutelevatorpushrodexit hole islocated
on the same side of thefuselage astheelevator control
horn.Locate theexit hole by gently runningyour finger
alongthesideof thefuselageoverthecovering.It
shouldbe located approximately1/2"infrontof the
stabilizerwhereshown.Usinga hobbyknife,remove
thecoveringfromtheelevatorpushrodexithole.
Locate the landing gear channel
Q24.Onthebottomofthefuselage,thereisa
channelforthemainlandinggear.Locatethis
channelby runningyourfingerover thecoveringon
thebottomofthefuselage.Usinga hobbyknife,
remove thecoveringfromthischannel.
J25. Trialfitthechromewirelandinggearstruts
intotheholes. Ittheywillnot go in easily,drilloutthe
two holes usingan 11/64"drillbit.Next,use thedrill
bitorhobbyknifetobeveltheinsidecornersof the
holes so thatthebend in thewirewillseat fullyinto
theholes.
Install the landing gear struts
Q26.Positionthetwo wirestrutsintheholesinside
thechannel.Centerthetwo landinggear straps over
thestrutsso theyareapproximately1/2"fromthe
sides of the fuselage. Markthe holes using a felttip
pen.
Drill the fuselage
Q27. Drillfourholesusinga 1/16" (1.6 mm)drillbit.
Mount the struts
Q28. Usingfour2.5 x 10mmself-tappingscrews,
fastenthelandinggearstrapstothebottomof the
fuselage over the struts.
15

Engine Selection
Thefollowingsteps29through36showthe
installationof componentsifa 2-strokeengineis
used. Ifyouareplanningtoinstalla 4-strokeengine,
youwillneedtoinstallthethrottleandsteering
pushrodson theoppositeside thanwhat is shown in
thephotos.Pay extraattentiontoanyspecialnotes
covering4-strokeinstallationinthetext.
Install the throttle guide tube
1-129. Cuta smallnotchthatis 1/8"wideand1/8"
deepintothefrontfuselageformerapproximately
3/4"downfromthetopof thefueltankopening.This
willgivethethrottlepushroda straighterlinetothe
servo. Cutthetwowhiteplastic pushrodguide tubes
sotheyareboth11"long.
Drill the steering pushrod exit hole
131. Measureandmarkthesteeringpushrodexit
ontothebottom of thefuselage1-3/4"back fromthe
fuselageand3/4"infromtheleftsideas shown.Using
a1/8"drillbit,drilla holethatanglesintowardsthe
backof thefuselageas shown.Be careful not to letthe
drillchuckdamage thecovering.
Install the steering guide tube
—132. Slidetheremainingguidetubeintothehole
youjustdrilledso that2-112"protrudes.Mix1/8oz. of
6-minuteepoxy. Gluethetubeintotheholeandinto
thelower leftslot insidethefuselage.Oncetheepoxy
has cured,trim off this tubeso it is flush withthe
bottom ofthefuselage (see photoatstep 36).
Make "Z" bends inthewire
Q30.Usingsandpaper,roughentheoutsideof both
plasticguidetubesandcleanwitha papertowel
dampenedwithrubbingalcohol.Thiswillhelpthe
gluesticktothetubes.Installoneof thetubesintothe
upperholeinthefirewall.Positionthetubeso that
approximately2" protrudesoutof thefirewall.Mix
1/8oz.of6-minuteepoxyandgluetheguidetubeinto
theholeinthefirewallandintothenotchinsidethe
fuselageas shown.Note:Ifyouareinstallinga
4-stroke,you willneed a new 1 /8"holeforthethrottle
pushrod.Drillthisholeso itlinesupbehind
thecarburetorarmonyourengine.Thepredrilled
holeisnotneededandshouldbepluggedwith
6-minuteepoxy.
D33.Makea Z-bendatoneendofbothofthe
1/16"x 18"wirepushrodsusingneedlenosepliers.
NOTE: Hobbicoofferspliersthateasilymakeperfect
Z-bends(HCAR2000). Seeyourhobbydealer.
Trim the steering arm
Q 34. Locate theblackplasticsteeringarm. I hold the
arminyourhandsothatthescrew holeis facingyou.
Usinga wirecutter,removetheleftsideof thearm
(rightsideifinstallinga fourstroke).Itisnotneeded.
16

Install the steering pushrod Assemble the fuel tank plug
_J 35.Attachthe"Z" bendofOne of thewiresintothe
outsideholeof theblackplasticsteeringarm.Slide
thewireintotheplasticguidetubesothatthescrew
holeonthesteeringarmis facingforward.Slightly
bend thewire as needed sothearm can be positioned
close to thenose gear mount(seephotoat step 36).
Install the nose gear strut
1-136.Installthenose gear strutthroughthesteering
arm,followedby a 4mmcollar.Next,slidethestrut
throughthenosegearmountandinstalla second
4mmcollarontothestrut.Tightenthewheel collars to
thestrutusingtwo3 x 5mmmachinescrews.
Position the steering arm
Q38.Pushonelongandoneshortaluminumtube
throughtheblackrubberstopper- thethird
aluminumtubewillnotbe used. Place thetwo white
plasticdisksover thetubes.The largerdiskshouldgo
towards theoutside. The nubon thesmalldiskshould
faceawayfromtherubberstopper.Insertthe
3x 18mm self tappingscrew throughthelargerdisk,
rubberplugandthenintothesmallerdisk.Do not
tightenthescrew at this time.
Bend the vent tube
-139.Bend thelongertubeupas shown sothatitwill
come within1/16"fromtouchingthetopof thetank
wheninstalled.Useyourfingerstobendthetube,
beingcarefulnotto kinkit closed.
Q37.Rotatethenosegearstrutso thatthewheel
(once installed)willpointstraightahead.Tightenthe
armto thestrutusinga 3 x 8mm screw. The screw will
leave a markon thestrut.Removethestrutandfile a
smallflatatthismark.Thiswillkeep thesteering arm
from slipingonthestrut.
Install the clunk
LJ40.Locatethemetalfuelpick-upweight(often
referredtoas the"clunk") andthefueltubing.Cutthe
fueltubingso itisonly5-1/2"long.Attachthefuel
tubingtotheshortaluminumtubeandtotheclunk.
17

Install the stopper Drill the hatch
41. The stopperassembly can nowbe insertedinto
thetank.The pressuretubeshouldbe adjustedsothe
tubeis pointedstraightupjustunderthetopof the
tank.The rubberstoppermustseat over thelipof the
tank.Makesurethatthetubesare positionedside-to-
side. Tighten the stopper by turningthescrew. Do not
over-tightenor you may strip out the plastic disk.
Install the foam collar and bend
the tubes
Q42. Locate thefoamcollar.Remove theinnerfoam
circleandplace thecollararoundtheneck of thefuel
tank.Bend thealuminumtubesoutward slightly.
Install the tank
Ul43.Withtheventtube(insidethetank)pointing
up,insertthefueltankintothefuselage.Makesure
the foam collar is seated well againstthefirewall.
Q44. Drillfour1/16" holes intothetankhatchas
shown in thesketch.
Install the hatch
Q45. Placethehatchontothefuselageanddrill
1/16"holes,usingtheholesinthehatchas a guide,
throughthehatchandintothemountingblocks.
Fastenthehatchusingthefour2 x 12mm
flangedsheet metalscrews.
Align the engine with the fuselage
_J 46. Positiontheengineon themountso thatthe
face of theenginethrustwasheris 1 /4"forwardof the
fuselagesides.Aligntheengineso thecrankshaftis
pointingstraightforward.Marktherailsatthefour
mountingholesusinga 5/32"drillbit(or a bitthatfits
yourenginemountingholesthebest)toscribe
amark.Note: You may need totrimthemounting
rails slightlyto fityourengine—this can be done with
aflatfile.
Front
18

Drill mounting holes
1-147. Removetheenginefromthemountanddrill
four1 /8" holes atthemarksyou justmade.
Attach fuel tubing to the tank
LI48. Cuttwo6" piecesof mediumsiliconefuel
tubing(notincluded).Attachonepiece ontoeach of
thealuminumtubescomingfromthefueltank.
Install the throttle pushrod
Q49.Attachthe"Z"bendoftheremaining
1/16"x 18"wirepushrodintotheinsideholeof the
carburetor controlarm.
Mount the engine
U50.Slidethethrottlepushrodwireintotheguide
tubeandpositiontheengineon themount.Installa
3mmflatwasherontoeachof thefour3 x 25mm
machinescrews. Insertthescrews throughtheengine
lugs andmountingrails.Installa 3mm flatwasheranda
3mm lock washer ontoeach screw alongwitha 3mm
hexnut.Tightenthehardwaretosecuretheengine.
Finally,applya dropof mediumCA ontothethreads
and nutsto prevent themfromvibratingloose.
Install the muffler
Attach the propeller to the engine
_152. Reamor drillthespinnerbackplatetofiton the
engine.Installthespinnerbackplate,prop, prop
washerandthepropnutontotheengine.Positionthe
propso itishorizontalwhentheengineisagainstits
compression(thepointatwhichyou feelresistance
whenyouturnthecrankshaftcounterclockwise).This
is a good habittoget intowheninstallingpropsonto
modelairplanes.Iftheenginequitsduringflight,the
propwillstophorizontally,thereforereducingthe
chanceof propbreakageif you areforced to land on
rough terrain.Useanadjustablewrench (not a pliers)
to securely tighten the propnut.
Install the spinner
_153.Trimthespinnerconeslotsifnecessaryso
thereis atleasta 1/16"gap betweenthecone andthe
prop. Once satisfiedwiththefit,attachthecone with
thescrews provided.Be carefulnottoover-tighten
these screws. Theyare threadedintoplasticwhichcan
strip out easily if they are over-tightened.
Q51.Installthemufflerontotheengineusingthe
screwsthatcamewiththeengine.Attachthefuel
tubingfromthe"vent"inthefueltanktothemuffler
pressuretap.Attachthetubingfromthefueltankto
thecarburetor.NOTE: Youmaywishtoshortenthe
fuellinesfora moredirectrouting.Makesurethatthe
linesdonotgetanykinkswhichcouldrestrict
fuelflow.
Prepare the servos
Ll54. Installtherubbergrommetsandbushings
includedwith yourradiosystem, ontothefourservos.
Referto yourradio manualforproper installationof
these items.
19

Install the servo tray support
Q55. Positiontheservotraysupportintothe
fuselagedirectlyinfrontof thethelandinggear block.
Glueinplace withthickCA.
Install the servo tray
Q56.Position theservo tray intothefuselage sothat
thesmallrectangularholeis facingforward.You may
need tosandtheedges andcornersslightlyfora good
fit.Glueinplace usingthickCA.
Install the servos in the fuselage
LJ57. Routingtheservowiresforward,installthe
servosintothetrayasshownusingthescrews
includedwiththeradio system. Enlarge theopenings
ifneeded.
Note: When installinga 4-strokeengine,thethrottle
servo shouldbe installedintheoppositedirection.
Chooseandtrimtheservoarmssotheylook similarto
theones shown in thephoto.
Install the aileron servo
Q58.Installtheremainingservointotheservo
mountinthewing.Routethewiresbetweenthetray
andthebottomof thewingas shown.
Receiver and battery installation
LJ59. Followingtheradiosystem'sinstruction
manual,plugthethreeservos intothereceiver.Next,
pluga servo extensionintotheaileronchannelof the
receiver.Finally,plugtheswitchintothereceiver.
Wrapthereceiverandbatterypackinfoamrubber
(HCAQ1U50)usingrubberbandsormaskingtapeto
hold thefoam in place. Installthebatteryand receiver
into(hefuselage.Thebatteryshouldhelocated
directlybehindthefueltank.Thereceivershouldthen
be placeddirectlybehindthebattery.Securethese
componentsinplaceusingpiecesofscrapwood
(popsiclesticksworkwell)gluedtothefuselagesides.
20