Hobbico Diabolo 40 User manual

ALMOST READY-TO-FLY RADIO CONTROLLED MODELAIRPLANE
•SUPERIOR QUALITY IN AN ALMOST-READY-TO-FLY MODEL
•SPECIAL COVERING PROCESS YIELDS A STRONG,
BRILLIANT, AND FUEL-PROOF FINISH
•90% COMPLETE OUT OF THE BOX—NO SANDING, PAINTING, OR
FINISHING REQUIRED
•SMOOTH, STEADY FLIGHT CHARACTERISTICS, JUST LIKE
AREAL PLANE
•CAPABLE OF FULL 4-CHANNEL AEROBATICS
©ENTIRE CONTENTS COPYRIGHT 1989, HOBBICO, INC.V1.0

IMPORTANT: BEFORE YOU BEGIN.
Congratulations on your choice ofan ASAP kitBEFOREyou beginassembly, carefully look through the box and
thoroughly read the instruction manual Also check the parts list against the items inthebox to be sure you have
everything that isonthe parts list Although we have taken great pains to simplify the building process, there are no
shortcuts to safety These instructions are your guide to safe and successful flying
Only after you are thoroughly familiar with the construction process should you proceed with assembly
REMEMBER! Under nocircumstances will a dealer accept a kitbackfor returnifassembly has
already begun.
Ifthe Diabolo 40 isnot quite what you expected, return it to your dealer inNEW and UNUSED condition
However, we think you will agreewith usthat the Diabolo40isone of the finest models of its type and will offer you
many hours of enjoyment
BEFOREASSEMBLY
CONSTRUCTIONHINTS:
(1)Trialfiteach part before gluingBe certain thattheparts fitproperly
(2)UsePlastiZapora thin type Cyanoacrylate gluefor installing
the plastic parts Donotuse too much as itmay runandspoilthe
appearance Donot get Cyanoacrylate on the foam partsof the Diabolo
Cyanoacrylatewill destroythe foam
(3)Itisbestto use 30minute epoxy where required Thisallowstime to
positionthepartsbeforethe epoxycures
(4)Beforeassembly,placeyourradiosystem oncharge
ADDITIONAL ITEMS
Most engines require a 1.5Vglow plug starting battery a glow plugclipanda
qualitybrandfuel(consulttheenginemanufacturer's recommendations)
The following items are needed for completing the Diabolo40kit
Medium FuelTubing (12 ")(1)
4045 Sized 2 Stroke (1)
or
60 70 Sized 4 Stroke (1)
4Channel Radio System (1)
Pacer PlastiZap CA Glue (1)
Screw Locking Compound (PacerZap Lock)(1)
Goldberg #481 Foam Rubber(1)
30Minute Epoxy (1)
Silicone Sealer (1)
Dubro 121E Z Connects (Optional) (2)
Dubro203 Kwik Switch Mount (Optional)(1)
TOOLS —
You will needthe following tools to assemblethe Diabolo40X Acto knife,
Phillips screwdriver (small and medium) needle nose pliers drilldrillbits sand
paper and ruler
Aquality brand engine willbeneeded We recommend the OS40FPor40SF
2stroke engine A prop and fueltubing will berequired for the engine
Afourchannel radio control system with4 servosisrequired for the Diabolo40
Thevariouscomponentsarepictured above
-2-

PARTSLIST
Before assembly match the parts inthe
exploded view of the Diabolo with the
parts inthe kit. Check off each part on
the parts list. Ifany parts are missing or
damaged returnthe kitto your hobby
dealer.
Check to make sure that allthe listed
parts are included inyour kit.
1Fuselage
2Right Wing
3Left Wing
4Wing Center Cover (Plastic)
5Vertical Fin
6Rudder
7Horizontal Stabilizer (Stab.)
8Cowl
9FuelTank
10Neoprene Ring
11 Plastic Disc(Small)
12Plastic Disc(Large)
13SiliconeTubing
14Clunk
153x18mm SelfTapping Screw
16RubberPlug
17Plastic Collar
Aileron Horn
Control Horns
SnapClevis
RodClevis
Back Plates
18FuelPipe
19Mounting Plates (Angled)
MountingPlates(Rectangle)
20 Clevis Retaining Tube
21Push Rod Exits
22 Stab.Root Cover (Plastic)
23 Wheel
24 MainGear
25 WheelPants
26 Cock Pit
27Canopy
28 Main Wing Joiner
29 RearWingJoiner
30Front Wing Joiner
31RubberShockAbsorber
32 Cowl Brace
33 Aileron Servo Tray Mount
34 Aileron ServoTray
358mm Dowel Rod
36 Wing Bolt Mounting Block
37BalsaTankSupport
38Wing Mounting Brace
393x12mm Self Tapping Screw
Spinner
SpinnerBack Plate
40Engine Mount
41Mounting Plates
42Shrink Tubing
43Control Rod(Short-Bent)
44Aileron Control Rods (Short)
45Throttle Control Rod (Long)
46Throttle Tube
47WoodPush Rods
48Control Rod (Long)
49MainServoTray
50 StabilizerSupports
51Plastic Disc
52 Cock Pit Mounts
53 Brass Sleeve
BrassTube
54 Tail Wheel
55 Spring Steel Strip
56 Tail Gear
57Tail Control Arm
58 Springs
59 BrassArms
600-Ring
61Collars
62Wheel Collar
634x40mm Screw
64 4x30mm Screw
65 2x15mm Screws
66 3x8mm SelfTapping Screw
673x8mm Screw
683x12mm Self-Tapping Screw
693x5mm Screw
703.5x15mm Screw
3x12mm Screw
714x15mm Screw
72 4x20mm Screw
73 4mm Nut
74 2mm Nut
75 3mm Nut
764mm Washer
773mm Washer
782mm Washer
79LockWashers
804mm Washer
814mm Nylon Nut
82 1/8" Plywood Wedge
-3-

WING ASSEMBLY
(A) Right Wing (Aileron Installed) ...1
(B) Left Wing (Aileron Installed) ....1
(C) Main Wing Joiner ......... 2
(D) Rear Wing Joiner ........ 1
(E) Front Wing Joiner ......... 1
(F) Wing Center Cover (Plastic) ....1
(G) 8mm Dowel Rods ......... 2
(H)Wing BoltMounting Block.....1
(3)Remove the foam covering fromthe aileron servo mounting area. Test fitthe
mainwing joiner and the rear wing joiner inthe right and left wing sections. The
dihedralangle of the joinersshouldmake thewing tipsslightlyhigherthanthe
center.
(I) Wing Mounting Brace ........ 1
(J) 4x30mm Bolts ........ .2
(K) 4mm Washer .......... .2
(L) 0-Ring . .............2
(M) Aileron Servo Tray .........1
(N) Aileron Servo Tray Mount.....1
(0) Main Servo Tray .......... 1
(1)Check each wing half forsmooth aileron operation. Itisa good idealto exercise
(move back and forth) the aileronstoinsureeasydeflection.Sandtheend ifany
rubbingisnoticed.
(4)Make sure thatthereisno gap between thewinghalves.Ifthere is,sandthe wing
joiner ends until thereis a tightfit.
(2) Align and epoxy thetwo main wing joiners together. Hold tightuntil the glue sets.
You'll notice thatthere is dihedralangle cut into the joiners somake sure they are
perfectlylinedup.
(5) Apply epoxy to one half of one side of both the main and rear wing joiners and
glue them to one wing half. Make sure the dihedral angle iscorrect and that they
areslidinalltheway.
-4-

(6)After the joiners have dried, applyepoxy where shown. The wing roots, the
wing joiners andinsidetheother wing joinerslotshouldbeevenlycovered with
epoxy.
(9) Drilltwo 8mm holesinto the wing joiners for the dowel rods.
(7)Slidethetwo wing halves together slowly and wipe off any excess glue.Hold
the two wing halves firmly together with tape untilthe epoxy hascured.
(10) Epoxythe Iwo dowel rods into the holes. Makesuretheyare all theway in.
(8)Oncedry, remove thetape. Position the front joiner as shown. The flat edgeof
the joiner should line upwith the top ofthe wing.next,removeandepoxy in
that sameposition Letcure.
(11)Position thewing center cover onthe bottom of the wing. Apply Cyanoacrylate
glueundertheedgesand holduntilitdries.
-5-

(12) Epoxy in the main servotray where shown
(15)Screw inthewing bolts half way into thewing bolt mounting block Apply ink
orpaint to the heads of the two bolts Next center the wing and setit onto the
boltsThiswillmarkwhereyouneedto drill
(13)Test fit the wing bolt mounting blockto the insideofthe fuselageThe blind
nutsshouldfacedown (16)After the epoxy has cured place the wing into the fuselage as shown Put the
front infirstaligning thedowelrodsinthe holesOnceinplacelowertheback
intoposition
(14)Epoxythe wing boltmounting block inThisisa highstresspointandextra
careshouldbetaken to ensurea strong joint(17)Place the wing mounting brace onto thewing as shown and center the wing
and brace with the fuselage NOTEThe two indentations onthe brace should
face upPlastiZapiton
-6-

(18) Drilltwo 4mm holes 90° from the top wing surface for the wing bolts where
thepaintmarks are.(21) Epoxy the aileron servo traymount into the rear section of thewing servo
mountandthenepoxy inthe tray.
COCKPIT/CANOPY ASSEMBLY
(19)Assemble the wing bolts as shown (bolt — washer — wing — o-ring) and
temporarily fasten down the wing. Check for goodfitand then remove.
(A) Cockpit, .................................... .1
(B) Canopy ..................................... .1
(C) Cockpit Mounts ................................ .4
(D)3x8mmSelf-TappingScrews...........................4
(20)Trial fitthe aileron servo tray mount and tray to the wing. NOTE: The front
edgeshould be on the wood, therefore, you will have to trim away a little
covering for a good fit.
(1)Epoxy the four cockpit mounts to the fuselage as shown. Becareful when
gluingthe rearmountstoonlygluethemto the wing mounting brace.
-7-

LANDING GEAR INSTALLATION
(2)Once the epoxy has cured, position thecockpit onthefuselage Make 4 small
holeswhere cockpit mounts are located Attach with the 4 smallself-tapping
screws Donotglue the cockpit
(A) Main Gear ...... .1
(B) Rubber Shock Absorber. ......1
(C) 4mmx30mm Screw ....... .2
(D)4mm Washer ....... .4
(E)4mmNut ...........6
(F) 4mm Nylon Nut.......... .2
(G)Wheel ............. .2
(H) Wheel Pants . . .2
(1)4mmx40mm Screw . . .2
(J) 3mmx12mm Screw ........ .2
(K) 3mm Washer ......... .2
(L)3mm Nut...........2
(M) Plastic Collar...........2
(3) Trail fitthe canopy to the cockpit Ifnecessary, trim for a perfect fitApply a thin
beadof Cyanoacrylate glueto the cockpit and attach and holdthe canopy until(1) Remove the cockpit and the wing Place the two 4mmx40mm screws with the
4mmwashers into the two landinggear holesthatare located inside ofthefront
fuselagesection
(4)Apply the black stripingtapeto the edgearound the canopy. (2)Thread two 4mm nuts onto the two screws and tighten Next place the rubber
shockabsorberover the screws.
-8-

(3)Now place the main gear (angled side facing back) over the screws and secure
itwith two 4mm nylon nuts NOTE tighten the nuts all the way and then
loosen them both one turn This will give the gear the correct shock absorbing
qualities
(6)Place the 3mm screw/washer into the top hole of the wheel pants from the
insideAnd thenattach ittothe topholeofthe maingearusingthe3mmnut
(4)Next take the two wheel pants and drilltwo holesineach one The first hole
should beat the indent (4mm indiameter) The second should be3/8above
the first andsmaller(3mmdiameter)
(7)Flare open thepants and insert the wheel assembly Installthe4mmnutand
tighten holding the inside nut with needle nose pliers
(5)Arrange the above parts as shown and then assemble together Dothis twice
Placescrewlockingcompoundonthethreadswheninstallingthe nuts
(8) Make sure thatboth wheels rotate freelyIfthey donot trim away the plastic as
neededOrif needbe,loosenthenutsunscrewthewheel screw,and
retighten
-9-

ENGINE INSTALLATION
(A) Engine Mount ............................... .1
(B) 4mmx20mm Screws .............................. .4
(C) Mounting Plates .............................. .2
(D) 4mmx15mm Screws ............................. .4
(E) 4mm Washers ................................. .4
(F) Lock Washers ................................. .4
(G) 3.5mm Screw ................................. .4
(H) 3.5mm Nuts .................................. .4
(3)Hold each mounting plate under one engine mount as shown (Thick side
towards the engine ) Lineupthe mark with the fronthole ofthe engine mount.
Markthe plateswhere theenginemountingholesare.
(1)Install the engine mount to the fuselage using (4) 4mmx20mm screws Note
the direction the mount isinstalled forproper engine positioning Also use
screwlocking compound onthe screw threads.
(4) Drilltwo 3.5mm holesineach mounting plateatthe marks.
(2) Make a mark 1/2"to 5/8" back from the hole on one end of each mounting
plate using a sharp knife NOTE:When mounting the engine, the thicker
sidesof theplates should bemounted facingthe engine
(5)Mount the plates to the engine using the 3.5mm screws and lock washers up
from the bottom as shown. Next apply screw locking compound to the screw
threads and tighten onthe 3.5mmnuts.Nowdothis to bothsides.
-10-

(6)Now mount the engine tothe fuselage Use(4)4mmx15mm screws with the
(4)4mm washers. Besure to usescrew locking compound onthe threads. (2) Put the self tapping screw inthe center hole from the large end and tighten it
only a coupleofturns.
FUELTANK INSTALLATION
(A) Fuel Tank ....................................1
(B) Clunk ..................................... .1
(C) Silicone Tubing ................................ .1
(D) Fuel Pipe ............................... .3 (1extra)
(E) Plastic Disc(Large) ............................... .1
(F) Plastic Disc(Small) ............................... .1
(G)3mmx18mm Self Tapping Screw. ....................... .1
(H) Rubber Plug ................................. .1
(I) Neoprene Ring ................................. .1
(J) BalsaTank Support ............................... .1
(3)Attach the silicone tubing to thecenteredfuelpipeandattachtheclunktothe
other end.
(1)Install two fuel pipes through the rubber plug. One should behalfwaythrough,
the other should be2/3through as shown. Next place the two plastic discs
ontoeach side.The large one should beonthe outside.
(4)Carefullybend upthe other fuel pipesoitwill justtouch the insidetop of the
fuel tank.
-11-

(5)Attach the complete fuel tank cap to the tank Make sure that the bent pipe is
pointingto the top Slide the cap onuntil the liponthe fuel tank isinthe
grooveofthecap.Then tighten the screw.
(8)Install the fuel tank from the inside of the fuselage with the fuel linesfacing
frontSlide thetank into its mount and upinto the hole infront of thefuselage
Make surethat the fuel tubing isthrough the hole.
(6)Glue the neoprene ring to the tank with silicone sealerAttach two pieces of
fuel tubing (6" each) to the pipes.Oneisfor thecarburetortheotherisfor the
pressure tap onthe muffler
(9) Epoxy the tank support to the insideof the front fuselage Once dryapply a
heavybeadofsiliconesealerinbetweenthe supportand the tank.
RADIO INSTALLATION
(A) Aileron Horn ......... 2
(B) Wood Push Rods ........ 2
(C)Aileron Control Rods(Short)...2
(D)Control Rod (Long) ....3
(E)Control Rod (Short-Bent) . . . . 2
(F) Shrink Tubing .......... 1
(G)Throttle Control Rod(Long)...1
(H) Snap Clevis .....2
(I) Push Rod Exits ........ 3
(J) Clevis Retainer Tubing ...... 1
(K)Throttle Tube . ......... 1
(7)Puta beadofsiliconesealeronthetopoftheneoprenering.
-12-

(1)Check the fitof your aileron servo inthe aileron servo tray You may have to
trim away some of the servo tray for a goodfitInstall the grommets onto the
servo and fasten itto the wing using the screwsprovidedwiththeradiosystem
Besure to leave the wire outside
(4)Attach the clevises to the aileron horns and slide on theretaining tubes After
checking the neutral position of the aileron servoand ailerons,put a mark on
the pushrodswherethe servoarmholesare
(2)Screw the aileron horns onto the aileron controlarmsTrimthewing mounting
brace as needed for fullaileron movement (5)At the mark,bendeachpushrodat a right angle
(6)Cut the push rods 6mm from thebend
(3) Screw two snap clevises half way upthe threads on the aileron control rods
Next, cut two pieces of the clevis retaining tubing and slidethem onto the rods
-13-

(7) Attach therods to theservo arm usingthe rodclevis NOTEYou mayhaveto
usea different style servo hornfor morethrow asshown
(10)Install the three remaining servos into the tray using grommets and screws Be
sure thatthe servos are positioned correctly Next mount the radio switch
NOTE Make sure that theservo wires allrunforward sothey are easily
accessible
(8)Connect the aileron servo to the receiver and check the movementofthe
ailerons Make sure that both ailerons are neutral when the servo isneutral
Adjust the clevises as needed
(11) We suggest installing anexternal switch mount sothat the radiosystem can
easily beturned on and off from the outside without taking the wing off (The
Dubro#203 Kwik Switch Mount works well)
(9)Trialfitthe servos into the fuselage and trim the tray as needed for a goodfit (12)Assemblethe rudder and elevator control rodsusing the parts above
-14-

(13)Bend two of the long rods as shown for the elevator and one of the rods for the
rudder (16)Assemble the push rod as shown Place the two short (pre bent) rods into one
end of each rod with thesingle grooves Slide a piece of shrink tubing over
each rodand heat with a heat gun ora lighter to shrink the tubing for a tight fit
Placethe elevator rodsinto the doublegrooved end of one of the rods
(14)Drilla 1/16" hole 2" from the ends (2 holes 1/16" apart on one end of one
rod) of both wood push rods and with a hobby knife Carefully cut straight
grooves from the holes to theends Only cut a groove onone sideof each end,
except for one end of one rod(the one with two holes) Forthis oneend,make
agroove onboth side
(17)Next, dothe samewith the other rodMake sure that eachrodfits ina groove
(15) Cut 4 equal (about 2" each) pieces of the white shrink tubing (18) Punch out the three rod exitsat the tailand insert the rudder push rod into the
fuselage from the frontand then through the bottom exiton the right side Do
the same withthe elevator rodbut put those through the top two holes Itmay
benecessaryto bend the rods to fit
-15-

(19)UsePlastiZap and glue the three plastic push rodexitsto the fuselage (22)Install the plastic tubing through the holeinthe firewallto theservotray Epoxy
the tube where itgoesin
(20)Check to make sure that the rodswill easilymove inand out with little
resistance You may have to bend the rods slightly for a perfect fit (We will
connect the rodsto the servos after the tail assembly )
(23)Make a "Z" bendonone end of the throttle control rodand insertthe opposite
end intothetube
(21) Usethethrottle control rod and the white throttle tube forthe engine linkage
Lightlysandthe plastic tube sothe epoxy will adhereto it(24)Connect the servos to the receiver and battery and center all radio controls
(including the throttle stick and move the servo horns sothey are inlinewith
the servo as shown Afterthey are centered pullthethrottlestick backdown
(low throttle) Install the straight servo horns
-16-

(25)Connect the "Z" bend to the engine throttle arm. Itmay benecessaryto
remove the arm from the engine for easierinstallation.(28) Next, at the marked point, make another "Z" bend,cut off the excess and
attach itto the servo arm. Foreasyadjustments, aneasyconnect can beused
here.(Dubro#121E-ZConnectorsworkwell.)
(26)Epoxy the white tube to the tubeguide. (29)Check for proper radiooperation ofthe throttle.Makesurethatthecarburetor
will move from low tohigh completely.
ASSEMBLY OF THE TAIL SECTION
(27) Fromthe inside, pull back thethrottlecontrolrod so the carburetoris closed.
Now, mark the rodwhere itcrosses the throttle servo horn(inlowposition). (A) Horizontal Stabilizer (Stab) .....1
(B) Vertical Fin.............1
(C) Rudder . ............ .1
(D) 1/8" Plywood Wedge ...... .1
(E) Stab Root Cover (Plastic)......1
(F) Stab. Supports ........... .2
(G) Plastic Disc ............ .4
(H) Brass Sleeve ........... .2
(I) 2mmx15mm Screw ........ .2
(J)2mmNut ..............2
(K) 2mm Washer ........... .4
(L) Tail Wheel ........ 1
(M) TailGear ............. .1
(N) Tail Control Arm ......... .1
(0) Springs ............. .2
(P) Brass Arms ............ .2
(Q)Spring Steel Strip (Long) ......1
(R) 3mmx12mm Self Tapping Screw. .2
(S) 3mmx5mm Screw. . 2
(T) Wheel Collar ....... 1
(U)Wheel Collar Screw 1
(V) Brass Collars . ....... 2
.17-

(1)Test fitthe 1/8"plywood wedge into the tail end ofthe fuselage. Ifthere isa
good fit,epoxy itinplace makingsure that itiseven with the fuselage sides.
NOTE:Itmay benecessaryto trimawaysomewoodorgluetomake the
wedgefitflush.
(4)Next take a piece of stringand attach it with a pin to the top centerof the
fuselage. Make sure thatthe stabilizer iscentered and stretch the ring to the
corner of the elevator. Adjust the positioning of the stabilizer sothat both
corners are the samelength when moving the string from sideto side.
(2)Trimaway partoftheplasticrearcoverto allowproperfitofthehorizontal
stabilizer.
(5)Next, remove the stabilizer and applyepoxytothewedge.Reinstallthe
stabilizer and re-centerlike before.
(3) Install the main wing. Next place the horizontal stabilizeronto the tailHold it
onand visually see ifthe wing and stabilizer are parallel. Ifnotsandthe higher
sideof the stabilizer mount until the stabilizer isparallel.
(6)Once the horizontal stabilizer epoxy has cured trial fitthevertical fin(without
therudder) on top of the horizontal stabilizer. Center the fin soitisstraight in
linewith thefuselage and 90° to the stabilizer.Drawa lineonbothsidesofthe
fin as shown.
-18-

(7)Next, apply epoxy to the top of the horizontal stabilizer and re-position the fin
between the lines. Make sure that the fin isstill90° to the stabilizer.Dothe
nextstep before the glue sets.
(10)Afterthe glue has completely set, assemble the tail wheel section shown. The
wheel should bestraight inline with the strip as should bethe tail control arms.
Attach the wheel collar tohold the wheel on.
(8)While the epoxy isstill wet. position the plastic stabilizer rootcoveroverthefin.
Doublecheck the positioning of the fin after doing this. (11) Carefully turn over the airplane and attach the 3mmx12mm self-tapping screws
into the center of the fuselage sothat the end ofspring steel strip is2 1/2" from
the end.
(9)When satisfied with the fin positioning, apply Cyanoacrylate glueto the
undersideedgeof the stabilizer rootcover and install inplace.(12)Now take the stabilizer supportsand bendthe ends as shown above.
-19-

(13)Attach the two supports onto the fuselage with a 3mmx12mm self tapping
screwMakesurethat the tailwheelassemblyisstraight(16)Next, drilla 2mm holeabout 1"deepat 1 1/8" from the bottom ofthe
rudderThe holeshouldbestraightinfrom the front edge
(14)Position the supports straight out (90°) to the fuselage and attach Usethe
includedhardware and drill2mm holes for mounting
(17)Notch a small groove(1/8" deep)fromtheholedowntothe bottomfor the
tail control arm
(15) Trial fitthe rudder onto the vertical finNotice where the bottom hinge meets
the fuselage and make a slotinthetailwherethe rudderhingeneedsto bewith
anX Acto knife
(18) Place a small amount of epoxy onthe hinges,inthe groove and onthe end of
the tail control arm (It isa goodideato place somepetroleum jelly onto the
hingecenter joint (point of movement) to keep out any epoxy
20-