Hobbico BrightStar 40 AWARF User manual

•Learntoflylow-wingswithAWARFease!
•Quick to build...flight-ready injust 16-20 hours
•Stable at low speeds—acrobatic atfull throttle
Features like this easy-access
enginepositioningwill make
BrightStarmaintenancefast
andsimple.
You'llquicklymakeasuccessfulstepupto flyinglow-wings withyourBrightStar40AWARE Its
90% prebuilt construction gets you outofthe workshop and ontothe flight line in only a matter
of hours. Then you can begin exploring the exciting acrobatic possibilitiesin the BrightStar's
low-mounted wing...without leaving behind the reasssuring durability and low-speed stability
ofyour basic trainer. Easyas1,2,3
Entire Contents © Copyright 1996 HCAZ3077 V 1.0

Y
ou'reabouttobuildinjustdayswhattookaviation
pioneersyears- a poweredmachinethatflies.Specially
created foryou andotherfirst-timeradiocontrolmodelers,
Hobbico'sBrightStaroffersnearlyalltheexcitementof
pilotinga real airplane...and develops skills that willtake you
anywhere you want in your new hobby.
Takea moment now to match the box contents with the
itemslistedhere.FollowingtheBrightStarassembly
instructions will be quite easy ifyou identify and organize
the parts before you begin.
Engine Mounting Parts
Part# Quantity
436-32x 3/4"machine screw.................4
44#6washers..........................................4
50Wire pushrods....................................2
57Pushrod guide tubes...........................2
59#6x3/4" sheetmetal screw................4
Tail Assembly
Please take your time and read through the instruction
manualbeforestartingto buildyournew airplane.If
you have any questions, please feel free to give us a call
at [phone].We hope you enjoybuildingand flying
the BrightStar 40.
Wing Assembly
Part# Quantity
1 Right wing with aileron............................. 1
2 Left wing with aileron...............................1
7Plywood wing joiners................................3
19 Wing center tape .......................................1
21 Aileron servo tray ......................................1
23Aileron control horns................................2
24 Threaded aileron pushrods ......................2
25Clevises......................................................2
28 Clear clevis retaining tube........................ 1
Part# Quantity
4Horizontal stab and elevator.........1
5Vertical finand rudder...................1
25Clevises...........................................2
26Control horns.................................2
28Clearclevisretainingtube.............1
36Dowel pushrods .............................2
462x15mm machine screws..............4
60Dorsal fin........................................1
61Dorsal fincovering.........................1
2

Landing Gear
Part# Quantity
10Main landing gearstrut.............2
11 Nose gear strut ...........................1
22Wheel Pant .................................3
27Plastic steering arm ...................1
29 Landing gear strap(Nylon) .......4
31Wheel ..........................................3
32Wheel collar / 3x5mm screw.....7
472.5xl0mm sheet metal screw....4
58Pushrod connector ....................2
62Landing gearstrap (Metal)........3
*Sketches shown are not
actual sizeortoscale.
InchScale
Fuselage & Parts
Part# Quantity
3Fuselage .................................1
8Wing mountingdowel...........2
20Servo tray ...............................1
40Stabilizer mountingbase......l
51Spinner...................................1
52Servo tray support.................1
Fuel Tank & Parts
Part# Quantity
12Fuel tank ..............................................1
13 Rubber tank stopper ...........................1
14 Fuel pick-upweight (clunk) ...............1
15Plastic stopper disk
(one large and one small) ...................2
16Aluminumfueltubing
(one short and two long) ....................3
17 3xl8mm sheet metal screw ................1
18 Silicone fuel line..................................1
33Foam tank collar..................................1
3

Glues
Choose a highquality6-minuteand 30-minuteepoxy, such
as GreatPlanes*Pro- Epoxy, whichhasbeen formulated
especially forR/Cmodel building.Pro Epoxies offera strong
bondanda varietyof curingtimes suitedforevery step of
assembly. You'llalso need a 1 oz. bottleof thinanda 1 oz.
bottleof mediumCA (Cyanoacrylate), plusrubbingalcohol
foreasy epoxy cleanup.
Hardware
Tools and accessories requiredforassembly
include a hobby knife, small and large Phillips
screwdrivers,needlenose pliers,drillwith
1/16", 11/64", 5/64",3/32",5/32" and3/16"
bits,ruler,#64rubberbands,onefootof
medium fuel tubing and petroleum jelly
Model Engine
Power yourBrightStarwithanyhigh-quality,
.40- .46sizemodel engine. The O.S..40LA is a
fineengine forthis plane. Look forfeatures such
as easybreak-in,easystarting,efficient
carburetionandlow maintenance.Checkthe
manufacturer'srecommendations forpropellers
to use with your engine.
Radio Equipment
Tocontrol your BrightStar's "flight path," you'll need a 1991
legal4-channelaircraftradiosystem withfourstandard
servos. Many4-channelradios includejustthree. You may
need to purchasethefourthseparately. Hobbico Command
servos are availablesingularlyand willworkgreat forthis
plane.The servos, batterypackand radioreceiver willbe
mountedonboardyourmodel andneed to be cushioned
fromjoltsand vibration. Half-inchthick foamrubbersheets
(HCAQ1050) areavailableforthispurpose.
Getting Ready for Flight
YourHobbicoBrightStarcan be readyfortakeoffinas littleas 16-20hours.
Yourhobbydealer or flying instructor(see next page) can help you decide what
accessories you'llneed forflight.Most are one-time-onlypurchases- likea
glow plugigniter(see glossary),fuelpump,and"chickenstick"orelectric
starter.You willalso need to obtainmodelglow fuel.Use glow fuelwitha
10-15% nitrocontentto keep yourengineperformingat itspeak.
General Items Required
Mixing Sticks (GPMR8055)
Epoxy Mixing Cups
Clothespins
Foam Rubber (HCAQ1050)
String
Felt-tipPen
Easy-Touch"BarSander
(GPMR6170)
150-grit sandpaper
(GPMR6183)
AdjustableWrench
MaskingTape
Medium3/32" FuelTubing
(GPMQ4131)
PaperTowels
T-pins
WireCutter
EpoxyBrush
SteelFile
WaxPaper
4

If you'rea beginner, thebest way
tobeginflyingyourBrightStaris
withanexperiencedR/Cpilotor
flying instructorat your side. You'll
learnfaster and avoid risking your
modelbeforeyou'retrulyready
tosolo.
Where do you findan instructor?
Askatyourlocalhobbyshop.
They'llhaveinformationabout
flyingclubsinyourareawhose
membershipincludesqualified
instructors.You should also jointhe
Academyof ModelAeronautics
(AMA),a 165,000 member-strong
nationalorganizationwithmore
than2,300 charteredclubsacross
thecountry.Throughanyoneof
them,instructortrainingprograms
are available.Contactthe AMA at
theaddressorphonenumber
below.
AcademyofModelAeronautics
5151East Memorial Drive
Muncie, IN47302-9252
[phone]
Fax[phone]
Before you fly:
1.Makesurethatno otherfliersare usingyour
radiofrequency.
2.Your radio transmitter must be the FIRST thing you
turnON,andtheLASTthingyouturnOFF.
3.Double check allcontrol surfaces, making sure theyarc
secureand move inthe proper direction.
4.Make sure that the transmitter & receiverbatteriesare
fully charged.
Fuel storage and care:
1.Do not smoke near your engine or fuel.
2.Store allengine fuelin a safe, cool, dry place, away
fromchildren and pets. Model fuelwillevaporate, so
makesurethatyoualwaysstoreitwiththe
cap secure.
When starting and running your engine:
1.Always wear safety glasses.
2. Makecertainthatyourglow plugclip is securely
attachedtotheglowplugandcannotpopoff,
possibly falling into the spinning propeller.
3.Use a "chicken stick" or electric starter to start the
engine - NOT your fingers.
4.Make sure that the wires from your starter and glow
plug clip cannot become tangled with the spinning
propeller.
5.Do not stand at the side of the propeller when you
startor runtheengine.Evenatidlespeed,the
spinning propeller willbe nearly invisible.
6.If any engine adjustmentsare necessary, approach
the engineonlyfrom behind the spinningpropeller.
90-Day Limited Warranty
Ifyou,astheoriginalownerofthismodel,discovera defectinparts
or workmanship within90days of purchase, Hobbico will repair or replace it, at
theoptionof ourauthorizedU S repairfacility,Hobby
Services, withoutcharge Ourliabilitydoes notincludecostof shippingto us
However, Hobby Serviceswill pay shippingexpenses to returnyourmodel to you
You mustprovide proofofpurchase, such as youroriginal purchaseinvoice or
receipt,foryourmodel'swarrantytobehonored
Thiswarrantydoesnotapplyto damageordefects caused by misuse or
improperassembly,serviceorshipment.Modifications,alterationsorrepairby
anyoneotherthanHobbyServices voids thiswarrantyWe aresorry,butwe
cannotbe responsible forcrash damage and/orresulting loss of kits, engines,
accessories, etc
Repair Service
YourBrightStar40 mustbe returned directly to Hobby Servicesforwarranty
work The address isHobbyServices, AttnService Department,1610 Interstate
Drive,Champaign,IL61821-1067Phone[phone],orforproduct
informationand technicalsupportplease contactusat(217) 398-8970
Please followtheinstructionsbelow when returningyourmodel This will
helpourexperiencedtechnicianstorepairandreturnItas quickly
aspossible
1ALWAYS return yourentiresystem, includingairplaneand radio.
2Disconnectthe receiverbatteryswitchharnessandmake surethatthe
transmitteristurnedoffDisconnectall batteriesanddrainallfuel
3Includea listof allitems returnedanda THOROUGH,writtenexplanation
of the problemandservice needed If you expect the repair to be covered
underwarranty,alsoincludeyourproofofpurchase
4Includeyourfullreturnaddress and a phonenumber where you can be
reachedduringtheday
Ifyourmodel ispast the 90-day warranty period or isexcluded fromwarranty
coverage, youcanstillreceive repairservicethroughHobbyServicesata
nominalcostRepairchargesandpostagemaybeprepaidorbilledCOD
Additionalpostage chargeswill be appliedfornon-warrantyreturnsAll repairs
shipped outsidethe UnitedStates mustbe prepaidinU S fundsonly
All pictures,descriptionsandspecificationsfoundinthisinstructionmanual
and onthe productpackageare subjectto changewithoutnotice
5

Special Note:
You should charge your radio system before starting to
build. Followingthe manufacturer's directions, connect
your transmitter and receiver batteries to the system's
charger. Thisway theradio willbe readywhen it istime
to installand test the components.
Prepare the wing joiners
bothsides of one of thewing joiners.Sandwich this
coated joinerbetween theremaining two. Make sure
that the centerlines drawn in step 1 are visable on both
sides of theassembly. Quicklyproceedthroughthe
followingsteps (3and4) before the glue cures.
Remove the excess epoxy
D1.Locatethethree1/8" (3mm) die-cutplywood
wing joiners.Arrange the"V'-shaped joinersin the
same orientation as they willbe glued together. Sand
off any bumpsfromthe edges. Draw a centerline on
two ofthe joiners as shown.
D3.Excessepoxywillsqueezeoutoftheseams
between the joinersand mustbe removed before the
epoxyis allowedtocure.Usea papertoweland
rubbingalcoholto remove the excess epoxy.
Glue the wing joiners
Note:Pleasereadsteps2through4beforemixingepoxy.
D2. Mix approximately 1/4 oz. (7.5ml) of 30-minute
epoxy using a mixing stick and a cup. Using a mixing
stickor epoxy brush,apply an even coat of epoxy on
Clamp the wing joiner
D 4. Use clothespins toclamp thewing Joinersfirmly
together.Ifany more epoxy squeezesout,remove it
using a paper towel. Make sure thejoiners are evenly
lined upwith each other. Set the joiner assembly aside
until the epoxy has fully cured.
6

Even the edges
D5.Using a bar sander or similartool, sand the wing
roots sotheywillfittogether with no gaps. Do not sand
toomuch or the dihedral angle could change.
Mark the wing servo cavity
D6.Marktheaileronservo locationon bothwing
panels using a felt-tippen. Using a hobby knife, cut an
openingintobothpanelsfollowingthelinesyou
justdrew.
wing joinerwillnot fit inthe cavity, lightly sand any
excess epoxy or uneven surfaces from thejoiner edges,
sides and ends.
Caution:Asnugfit isdesirablebetween thejoinerand
thewingcavity.Donotsandexcessively.
Viewing the wing dihedral
D8.Pay close attentiontothe orientationofthewing
joinerinrelationtothewingpanel,creatingthe
dihedralangleas shown.Test fitthewingpanels
together.Theyshouldfitflush against each other
without gaps.
Note! When performing the following steps, be sure
to use a sufficient amount of epoxy to forma complete
and solidbond between theplywood wing joinerand
the two wing halves. This isthe most important glue
joint inthe entire airplane.
Please read through the following three steps before
mixing any epoxy. You must complete these steps
within 20minutesfrom the timeyoumix theepoxy.
Glue the joiner
Test fit the wing joiner
D7. Test fitthewing joinerin both wing panels by
slidingthe joinerinto the joiner cavity inthe wing. The
joiner should slidein snugly up tothecenterline. If the
D9. Mix 3/4oz. (22ml)of 30-minuteepoxy. Use a
mixing stick or epoxy brush to apply epoxy to allfour
sides of thejoinercavity. Insertthejoinerintothe
cavity up to the centerline marked on the joiner plate.
Be sure you are installing the joiner correctly. Quickly
proceed to the next step.
7

Apply epoxy to the wing root rib Test fit the aileron servo
D10. Applyepoxyinsidethejoinercavityofthe
remaining wing panel. Next, coat the wing root ribs on
both panels. Quicklyproceed to the next step.
Join the wing halves
D11.Assemble the two wing halves with the tightest
seam possible. No gaps should be showing between
the two wing halves. Clean any excess epoxy fromthe
outsideof thewing usinga papertowel dampened
with rubbingalcohol.Use several stripsof masking
tapeon bothsides toholdthewing halves tightly
together. Let the epoxyfullycure before continuing.
D13.Testfitthe aileron servo into the servo tray and
the hole in the top of the wing. Enlarge either hole, if
needed, with a hobbyknife or a fine-toothedfile until a
properfitis achieved.The plywood tray shouldnot
actuallycontactthethesides of theservo. Leave a
1/64" gap allthe way around. Remove the servo. The
servo should not touch any of the wing surface.
Install the servo tray
Trim the covering
D12.Hold the plywood aileron servo trayover the
hole in the top ofthe wing. Trace the outside of the tray
with a felt-tippen and then remove the tray fromthe
wing. Carefully removethecovering within thelines
usinga new #11blade in a hobby knife, being careful
notto cut into the balsa wing sheeting.
D14.Mix l/8oz.(3.5ml)of6-minute epoxy to glue the
servo tray to the topside of the wing. Attach the servo
tray to the topof the wing. After the epoxy has cured,
cuta small notchin the servo tray toallowthe servo
lead to pass through.
Apply the wing center tape
D15.Starting at thefrontof the aileron servo tray,
applythe1/2"(12.5mm) whitewingcentertape
8

completely aroundthewing over thejoint.A small
amountof pressureshouldbeappliedto makea
smooth seam.
Check the aileron hinge
D16.Gentlytugon each of the ailerons at each hinge
location. If any of the hinges are loose, reglue them as
described here. First, flex the surface allthe way one
direction (DO NOT REMOVETHEAILERON).
Install the aileron control horns
D17.Thread the aileroncontrol horns onto the torque
rods until there is3/4"(19mm) of torque rod between
the wing and control horns.
Assemble the pushrods
Apply5 drops ofthinCAonto eachhinge.
NOTE: Do notuse CA acceleratoras theCA must
"wick"into the slot. Use a paper towel to absorb any
excess glue. Wait a few minutes forthe glue tocure,
then flex the surface the other direction and glue the
otherside of the hinges in thesame manner. Finally,
flex the surface back and forthseveral times tofree up
the aileron.
D18.Locate two plasticclevises andtwo 8 (203mm)
aileronpushrods.Threadtheclevisesontothe
threaded end of the pushrodsuntiltherodprotrudes
between the clevisforks 1/16".
Install the pushrods
D19.Attach the pushrods to the aileron control horns.
Press theforksof theclevis togetheruntiltheysnap
into place.
9

Securing the aileron pushrods Install the wing mounting dowels
D20.Locatethe1/4"(6.5mm)diameterclear
retaining tube and cut two 1/4" (6.5mm) pieces. Slide
one piece ontoeach clevis tosecure the connection
between the clevisand the horn.
Thisconcludes the wing assembly fornow. Tape the
pushrods to thewing to keep them in place until you
installthe servo.
D2. Insertbothwingmountingdowels so they
protrudean equal distance on both sides. Mix 1/4oz.
(7.4ml)of 30-minuteepoxy. Apply gluearoundthe
dowels next to the fuselage and slidethem inand out
tohelpforcetheglueintotheholes. Using a paper
towel, spread the excess glue aroundthe ends of the
dowels. Thiswill fuelproofand addstrengthtothe
wood.Fromtheinsideof thefuselage,applymore
epoxy around the dowels where they meet the sides of
the fuselage. These wing dowels willbe used as anchors
for rubberbands to hold the wing in place. Wipe off all
excessepoxy with a paper towel and rubbing alcohol.
Locate the wing dowel holes
D1.Locate thefourround holes (two on each side of
thefuselage,see photobelowforreference)and
remove the covering over each hole.
Caution: Do not cut out the rectangularholesin the
sideofthefuselage.
Locate the stabilizer slot
D3.Locatethehorizontalstabilizerslot underthe
covering on the tail section of the fuselage by pressing
lightlywithyourfinger. Theslotis locatedon both
sides ofthe tail.Using a hobby knife, carefully remove
the covering,exposing the slots.
NOTE:Donotcutintothewoodaroundtheslot.
10

Install the plywood stabilizer mount Locate the vertical fin slot
D4.Locatethe1/8"(3mm)plywoodstabilizer
mounting base and testfitit into thebottomof the
horizontalstabilizerslot.Lightlysandthebaseif
necessary toobtain a good fit.Remove the base from
thefuselage.
D7. Using yourfinger, locate the vertical fin slot on
thetopof thefuselage.Remove thecoveringwith a
hobbyknife.
Check the rudder and elevator hinges
Glue the mount In place
D5.Mixl/8oz.(3 5ml) of 30-minute epoxy. Using a
mixing stick, apply a generous amount of epoxy into
theslotandpositionthestabilizermountingbase
firmlyin position.Removeanyexcessepoxythat
remains on the topof the stabilizer base and on the
outside ofthe fuselage with a paper towel and alcohol.
Remove the tail post
D6.The balsa tail postis locatedat the rear of the
fuselage, behind the horizontal stabilizer slot. This post
was left formanufacturingalignment. The post must
be removed inorder to insert the horizontal stabilizer.
Using a sharp hobbyknife or razorsaw, cut the post
even with the slot as shown inthe picture.
D8.Gentlytugon therudderand elevatorateach
hinge location.If any of thehinges are loose, reglue
them as described here: First, flex the control surface
all thewayonedirection(DO NOT REMOVETHE
CONTROL SURFACE).
Apply 5 drops of thinCAonto each hinge.Usea paper
towel to absorb the excessglue. Wait a few minutes for
the glue to cure, thenflexthe surface the other direction
and glue the otherside of the hinges. Finally, flex the
surface backandforth severaltimesto free itup.
NOTE: Do not use acceleratoron the hinges.
11

Mark the centerline Align the stabilizer with the fuse
D9.On the topsurface of thehorizontal stabilizer,
measuretofindtheexactcenterfromside toside.
Draw a "centerline" using a felt-tippen. Next, extend
that line ontothetrailingedge, in thehinge gap, as
shown. (DO NOT MARK ON THE ELEVATOR.)
EQUALMEASUREMENTS
D11.Attach a piece of string with a T-pin to the center
of the fuselage asshown. Hold the string to one corner
of the horizontal stabilizer. The distance from the pin
to thehorizontal stabilizer must be exactlythe same to
both corners.
Mark the stabilizer location
Align the stabilizer with the wing
(DO NOTUSE GLUE IN THIS STEP)
D10.Insert the stabilizer into the horizontal stabilizer
slot so it iscentered in the fuselage (A). Place the wing
onto the fuselage and secure it with two rubberbands
viewtheplanefromthereartocheckforproper
alignment.The stabilizer should be parallel with the
wing (B).Ifnot,sand the highside of thestabilizer
mounting plate a little at a time until correct.
D12.With the stabilizer properly aligned, use a felt-tip
pen to trace a line around the tail of the airplane on the
top and bottom ofthe horizontal stabilizer.
Removethecentercovering
D13.Remove the stabilizer and draw two additional
lines,on the topand bottom,1/16" inside thelines
12

drawn inthe previous step. Next, carefully cut through
the covering using a new #11knife blade at the inside
linesand remove the covering from the center. Do not
cutthewood under thecovering!This wouldseriously
weaken the stabilizerand could easily cause the
stabilizertobreakin flight. Ifthe stab breaks theplane
may crash, sobe very carefulwhen you make this cut.
If thecovering is notremoved fromthestabilizera
proper bond cannot be achieved.
Install the Dorsal Fin
Install the stabilizer
D14.Mix l/4oz.(7.5ml) of 30-minute epoxy.Using a
mixingstick, place epoxy insidethe horizontal stabilizer
sloton allsidesincludingthehorizontalstabilizer
mount. Place more epoxy onto the bottom and topof
the stabilizer where you removed the covering. Insert
the stabilizer fromthe rear and adjustthe alignment.
Wipe offany epoxy thatsqueezesoutusinga paper
towel dampenedwith rubbingalcohol. Recheck the
alignment,severaltimeswhilethe epoxycures.
Install the vertical fin
90°
D16.Locate the precutdorsal fin and decal. Apply the
decal to the dorsal fin, starting at the topand working
the decal down the sides. Trim any of the excess decal
so thatit doesn't hang fromthebottomof thefiller.
Carefullytrimaway thecoveringfromthefuselage
wherethefilerwill bepositioned. Glue the filler in
place usingMedium CA.
Cut the rudder pushrod exit
D17.The precutrudderpushrod exit hole islocated
on topof the fuselage on the left side of the fin. Use a
hobbyknife to remove the covering fromthe rudder
pushrod exithole.
Cut the elevator exit
D15.Test fitthe vertical fin into the slotinthe top of
the fuselage. Sandthe edges of the slot ifnecessary for
asnug fit.When fitproperly the bottomof the vertical
finwill restfirmlyagainst thetopof the horizontal
stabilizer.Mix l/4oz.(7.5ml)of 30-minuteepoxy.
Using a mixing stick,applyepoxy tothetopof the
horizontal stabilizer through the slot. Apply epoxy to
the sides and bottomsurfaces of the finbase that have
balsa wood exposed. Insert the fin into the slot. Check
fora 90°anglebetweenthefinand thehorizontal
stabilizerwhenviewingfromtherear.Checkthis
alignment several times as the epoxy cures. (You may
find it beneficial tohold the fin inplace with tape until
the epoxycures.)
D18.The precut elevator pushrod exithole islocated on
therightside of the fuselage. Locatethe exit hole by
gently running your finger along the bottom sideofthe
13

fuselageoverthecovering.Itshouldbelocated
approximately1/2"in frontof thestabilizerwhere
shown. Use a hobbyknife to remove the covering from
theelevatorpushrodexithole.
straps(from plastic parts tree) over the strutssothey
are approximately 3/4"fromthe ends of the channel.
Marktheholesusingafelt-tippen.
Locate the landing gear channel
D19.There isa channel forthe main landinggear on
the bottomofthe wing. Locate this channel byrunning
yourfingerover thecoveringon thebottomof the
wing. Use a hobby knife to remove the covering from
thischannel.
Drill the fuselage
D22. Drillfour holes forthe landing gear straps using
a1/16"(1.6mm) drillbit.
Mount the struts
Prepare the channel for the gear
D20. Test fitthe chrome wire landing gear struts into
the holes. If they willnot go ineasily,enlarge the two
holes using an 11/64" drillbit. Next, use the drillbit or
hobby knife to bevel the inside corners of the holes so
that the bend inthe wirewillfully seat into the holes.
Install the main landing gear struts
D23. Use eight2.5xl0mmself-tappingscrews to
fasten the landing gearstraps to the bottom of the wing
over the struts.
Engine Selection
D24. Steps25 through42 show theinstallationof
components fora 2-stroke engine. If you are planning
to installa 4-stroke engine, you willneed to installthe
throttle pushrod on the opposite side ofwhat is shown
in the photos. Pay close attention toany specialnotes
covering4-stroke installationin the text.
Glue the throttle guide tube in place
D21.Position the wire landing gear strut inthe hole
inside the channel. Center the two nylon landing gearD25. Use sandpaper toroughen the outside of both
plasticpushrodguidetubesand clean them witha
14

paper towel dampened with rubbing alcohol. This will
helpthe glue adheretothe tubes.Insertoneof the
tubesinto theupper hole inthe firewall.Position the
tubeso thatapproximately1"protrudesoutof the
firewall.Mix l/8oz.of 6-minuteepoxy and glue the
guide tubeinto the hole in the firewall.
Note:If you are installing a 4-strokeengine, you will
need to drilla new 5/32" hole for the throttle pushrod.
Drillthis hole soit linesup behind the carburetor arm
on your engine.The predrilled hole isnot needed and
shouldbe pluggedwith 6-minute epoxy.
Make "Z" bends in the wire
D28.Make a Z-bend at only oneendof each of the
1/16"x 18"wire pushrods using needle nose pliers.
NOTE: Hobbico offerspliers thateasily make perfect
Z-bends (HCAR2000).Seeyour hobbydealer.
Trim the steering arm
Drill the steering pushrod exit hole
D26. Drill a 5/32"holethroughthefirewall,5/16"
fromthe bottom and 5/8" fromthe inside edge of the
fuselageside.
D29. Locate theblack plastic steering arm. Hold the
steeringarm in yourhand so thatthescrew holeis
facingyou. Using awirecutter, remove the right side of
the arm.
Note:All directionsarebaseduponyou sittingin
the cockpit.
Install the steering pushrod
Install the steering guide tube
D27. Slide the remaining guide tubeinto the 5/32"
hole you justdrilled so about2" - 3"protrudes.Mix
1/8oz. of 6-minute epoxy. Glue the tubeinto thehole
and intothe lowerleft notch inside the fuselage. Once
the epoxyhas cured, trim offthistube soit isflush with
the firewall.
D30.Attach the "Z"bend of one of the wires into the
hole closest tothe center of the black plastic steering
arm. Slide the wire into theplastic guide tubeso that
the screwhole on the steering arm is facing forward.
15

Install the nose gear strut
D31.Install thenose gear strut through the steering
arm, followed by a 4mm collar.Slidethe strut through
the lower lug on the engine mount.Slide the strut up so
thatthecoil is about1/4"below thebottomof the
fuselage. Tighten the wheel collar tothestrutusing a
3x 5mm machine screw.
Position the steering arm
D32. Rotatethenosegear strutso thatthewheel
(once installed)will pointstraightahead. Swing the
steeringarmso itis approximately1/2"fromthe
firewall. Tighten the arm to the strut using a 3 x 8mm
screw.The screwwillleave a mark on the strut. Remove
the strut and file a smallflatat this mark. This willkeep
the steering arm from slippingon the strut.
Assemble the fuel tank plug
D33.Pushone longand oneshortaluminumtube
through the black rubberstopper - the third aluminum
tubewillnot be used. Place the two white plastic disks
over the tubes.The larger disk should go towards the
outside. The nub on the smalldiskshould face away
fromtherubberstopper.Insertthe3 x 18mm
self-tapping screw through the larger disk, rubberplug
and thenintothesmallerdisk.Do not tightenthe
screw at thistime.
Bend the vent tube
D34. Bendthelongertube(pressuretube)upas
shown so thatit willcome within 1/16" fromtouching
the topof the tank when installed. Use your fingers to
bend the tube, being careful not to kink it closed.
Install the clunk
D35.Locatethemetalfuelpick-upweight(often
referred to asthe "clunk") and the fuel tubing. Cut the
fuel tubing so it is 3-1/2" long. Attach the fueltubingto
the short aluminum tube and to theclunk.
Install the stopper
D36.The stopper assemblycannowbe inserted into the
tank.The pressuretube should be adjusted sothe tube is
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pointed straight up justunder the top ofthe tank. The
rubber stopper must seatoverthe lipof the tank.Make
sure that the tubes are positioned side-to-side. Tighten
the stopper by turning the screw.Do not overtighten or
youmaystripthe threads inthe plasticdisk.
Install the foam tank collar and bend
the tubes
D37. Locatethefoamtankcollar.Removethe
innerfoamcircleandplacethecollararoundthe
neckof thefueltank.Bendthealuminumtubes
outward slightly,asshown.
Install the tank
D38.Insert the fueltank into the fuselage. Make sure
the foam collarisseated wellagainst the firewall.
Attach fuel tubing to the tank
D39.Cut two 6"pieces ofmedium silicone fuel tubing
(notincluded).Slideonepieceontoeachof the
aluminum tubes coming fromthe fueltank.
Install the throttle pushrod
D40. Attach the "Z"bend of the remaining 1/16" wire
pushrodintotheinsideholeof thecarburetor
control arm.
Mount the engine
D41. Insertthethrottlepushrodintothepushrod
guide tubeand positionthe engine on the mountso
thatthefaceof theenginethrustwasheris1/4"
forward of the fuselage sides. Align the engine sothe
crankshaft ispointing straightforward.
Using theengine mounting plates, 6/32"lock washers,
6/32"nutsand 6/32"x 3/4"screws, secure theengine
into position.
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Install the muffler Install the spinner
D42.Installthemufflerontotheengineusingthe
screwsthatcamewiththeengine.Attachthefuel
tubing from the "pressure tube" in the fuel tank to the
mufflerpressure tap. Attach thefuelpick-uptubefrom
thefueltankto the carburetor. NOTE:You maywish to
shortenthefuellines formore direct routing.Make
sure thatthelines do not get any kinks which could
restrictfuelflow.
Attach the propeller to the engine
D43.Install the spinner backplate, prop, prop washer
and the propnutonto the engine. Position the propso
it is horizontalwhentheengineis againstits
compression (thepoint at which you feel resistance
when you turn the crankshaft counterclockwise). This
isa good habit to get into when installingprops onto
model airplanes. If the engine quits duringflight, the
propwill stophorizontally,thereforereducingthe
chance of propbreakage if you are forced toland on
rough terrain. Use an adjustable wrench (not a pliers)
to securelytighten the prop nut.
D44.Trimthespinnerconepropellerslotsif
necessary sothere is at least a 1/16" gap between the
cone and the prop. Once satisfied with the fit,attach
the cone with thescrews provided. Be carefulnot to
overtightenthesescrews.Theyarethreadedinto
plasticwhichcanstripouteasily if theyare
overtightened.
Prepare the servos
D45. Installtherubbergrommetsandbushings
included with your radio system, onto thefourservos.
Refertoyourradio manual or thesketch forproper
installation ofthese items.
Install the servo tray support
D46.Position the servotray supportin the fuselage
whereshown.Glueitinplacewith thickCA.
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Install the servo tray Receiver and battery installation
D47. Position the servo tray inthe fuselage. You may
need to sandthe edges and corners slightly for a good
fit.Glue it inplace using thickCA.
Install the servos in the fuselage
D48.Routethe servo wires forward. Install the servos
into the tray as shown using the screwsincluded with
theradiosystem.Enlargetheopeningsif needed.
Choose and trim the servo arms sothey look similarto
the ones shown inthe photo.
Install the aileron servo
D49. Routetheservowiresthroughtheharness
notch that you made inthe servo tray instep 14.Install
the servo.
D50.Following the radio system's instruction manual,
plugthethreeservos intothereceiver. Next,pluga
servo extension into theaileron channel of the receiver.
Finally,plugtheswitchintothereceiver.Wrap the
receiverand batterypackin foam rubber(HCAQ1050)
using rubberbands or masking tape to hold the foam
inplace.Installthebatteryandreceiverintothe
fuselage. The batteryshould be located directly behind
thefueltank.Thereceivershouldthenbeplaced
directly behind the battery. Secure these components
in place using pieces ofscrap wood (mixingsticks work
well) glued to thefuselage sides.
Mount the switch to the fuselage
D51.Cutouttheopeningon theleftsideof the
fuselage forthe switch and install it using thescrews
included with the switch. We recommend using a Great
PlanesSwitch/ChargeJack(GPMM1000,shownabove).
Thismakesiteasy andconvenienttochargeyour
receiverbatteries. It isgood practice to always installthe
switch on the side opposite the engine's exhaust outlet.
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Prepare the pushrods Align the control horns
D52. Locatethetwo wooden dowel pushrodsand
applythinCA to the ends of theshrink tubingon
both rods.
Install the pushrods
D53.Insertthetwo pushrods,threaded end first,
through the fuselage and out the two pushrod exits at
the back ofthe fuselage.You mayneed to bend the rods
slightly toeliminate binding, butkeep any bends to
aminimum.Excessivebendingof thepushrodwill
allowitto flex during operation.
Make the clevis retainers
D54.Cut two 1/4" long pieces ofthe cleartube. Slide
oneon each of thepushrodsthatprotrudeoutof
the rear ofthe fuselage.
Install the two clevises
D55. Screwa clevis ontoeachpushroduntilthe
threads protrude about 1/16"between the clevisforks.
Connect the control horns
D56.Attach the two clevises to thecontrol horns as
shown. Use thesecond hole fromthe outsideforthe
elevator and the thirdhole from the outside hole for the
rudder. Check to make certain that the pushrods do not
bindintheopeningsandthattheyoperatesmoothly.
CORRECT INCORRECT
D57.Position the control horn on theelevator sothat
the pushrodwillwork without binding. Mark the two
holes using a felt-tip pen. Make sure that the control
hornsarepositionedeven with thehingeline (see
sketch). Repeatthisprocess forthe rudder.
Secure the control horns
D58.Drill two 3/32"(2.4mm) holes straight through
the balsa elevator at the marks. Insert two 2 x 15mm
machinescrews throughthecontrolhornandthe
elevator, finally threading them into the control horn
backplate.Tighten thescrews butdo notcrushthe
balsa. Cut off the excess threads that stick out usinga
wire cutter. Repeatthis process forthe rudder.
Attach the pushrods
D59.Slidethe clevisretainers over the clevisforks.
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