Hobbico starfire 40 User manual

STARFIRE 40
Almost-ready-to-flyRadioControlledModel Airplane
•Superior quality in anAlmost-Ready-to-Fly model
•80%complete out ofthe box - No Sanding,Painting, orFinishing required.
•Beautiful sporty appearance.
•Superacrobatic aircraft for experienced pilots
•All wood construction with sheeted wings
•FuelTank, Spinner,Wheels, LandingGear,EngineMount, andHardware areincluded.
WINGSPAN: 551/2in.
LENGTH: 49 3/4in.
WING AREA: 534sq.in.
WEIGHT: 5 1/2pounds
ENTIRE CONTENTS© 1991,HOBBICO , INC.V1.0
RADIO: 4 channel(notincluded)
ENGINE:.40 Performance2-cycle (not included)
or .61-.914-cycle (notincluded)
ACCESSORIES: Standardfieldequipment(not included)

IMPORTANT: BEFORE YOU BEGIN.
Congratulations on your choice ofan AWARF kit.BEFORE you begin assembly, carefullylook through the box and
thoroughly read theinstruction manual.Check theparts listagainsttheitemsinthe box to be sure you haveeverythingthatis
on thepartslist.Althoughwe have taken great painsto simplifythebuildingprocess, there are no shortcuts to safety. These
instructionsare yourguideto safeandsuccessfulflying.
Onlyafteryou are thoroughlyfamiliarwiththeconstructionprocess shouldyou proceed withassembly. Remember! Under
nocircumstances willa dealer accept a kitbackforreturn ifassembly has alreadybegun.
If theStarfireis not quitewhatyouexpected, returnit to yourdealer inNew and Unused condition.However, we think you
willagree withus thattheStarfirekitis one of thefinestmodels of itstype andwillofferyou manyhoursof enjoyment.
BEFORE ASSEMBLY
CONSTRUCTION HINTS:
1.IMPORTANT! Trial fiteach part before gluing.
Becertain thatthe parts fitproperly.
2.Use PlastiZapor a thintypeCyanoacrylate glue for
installingtheplasticparts.Do not use too much,as it
may run and spoil the appearance.
3.It is best to use 30minute(orlonger)epoxy for
assembly.This will allow time to position the parts
before theepoxy cures.
4. Before assembly, place your radio system on charge.
5.There is a metricruleron page 3 to aid in findingthe
correct screw or partsizes.
ADDITIONALITEMS
The followingitems are needed for completing the
Starfirekit:
MediumFuel Tubing (12") .................................................1
.40 Sized 2-Cycle Engine....................................................1
OR
.61- .70 Sized 4-Cycle Engine............................................1
4- ChannelRadioSystem.................................................1
Pacer PlastiZapCA Glue....................................................1
Goldberg #481 Foam Rubber.............................................1
Hobbico(HCAR3950) 30-Minute Epoxy............................1
Silicone Sealer.....................................................................1
Dubro 121E-Z Connects (Optional)...................................2
Hobbico (HCAR3760)Threadlock......................................1
Dubro340 inlineFuel Filter.............................................1
Propeller (Sizedependson the engine) .............................1
Starter
12V Battery
Glow Driver
Standard fieldequipmentisrequiredforrunningtheengine:
Starter, 12VBattery,Hot Shot Glow Plug Driver and compatible
glow enginefuel.
O.S. 70Surpass
4-cycle
O.S. .40 SF
2-cycle
Glow Fuel
lSeeEngines
Recommendations)
REQUIREDFOR RUNNINGTHEENGINE
TOOLS
You willneedthefollowingbasictools to assemblethekit.Hobby
knife.Phillipsscrewdriver(smallandmedium),needlenose pliers,
drill,drillbits, sanding block, ruler,andstring.
Aqualitybrandenginewillbe needed. We recommend the O.S.
.40SF2-Cycle engineor theO.S. 70 Surpass4-cycleengine.
RADIOSYSTEM
Afour-channel radio control system with4 servos isrequired for
the Starfire 40.
2.

PARTS LIST
Before assembly, match the parts in the photo on this page with
the parts inthekit.Check off each part as they are located. If
any parts are missing or damaged, consult yourhobby dealer.
()1 Fuselage.........................1
( ) 2 Right Wing.....................1
( ) 3 Left Wing.......................1
() 4 7mm Dowel Rod ............2
() 5 Wing Joiner ...................1
() 6 ReinforcingBlocks ........2
() 7 Wing Center Cover........1
() 8 Hinges............................13
() 9 Ailerons..........................2
() 10Aileron Servo Tray........1
() 11WingMountingBlocks..3
()12 Blind Nuts.....................2
()134 x 30mm Wing Screws.2
() 144mm Washers ................2
() 15 0-Rings..........................2
() 16MainGear Struts..........2
() 17Plastic Tree....................1
()183 x 15mm S/TScrews....8
() 19Bellcrank.......................1
()203 x 8mm Screw ..............1
() 21Front Gear Strut...........!
() 22 White Tube ....................2
() 23 450mm Rod....................2
() 24 Wheel Collars ...............7
() 25 3 x 5mm Screws ............7
() 26 Wheels ...........................3
() 27 MountingPlates............2
() 28 3 x 15mm Screws ..........8
() 29 Lockwashers..................8
() 303mm Nuts......................4
() 31 Wing Pad .......................1
()32Cowl Decal.....................1
() 33 Fuel Tank ......................1
() 34Rubber Cap....................1
() 35Fuel Tank Clunk...........1
() 36 Fuel Line .......................1
() 37 Fuel Pipes......................3
()383 x 18mmS/TScrew .....1
()39Large Disc......................1
() 40 Small Disc......................1
() 41 Neoprene Ring...............1
() 42 Clevis Retaining Tube...l
()43 Bent Rods ......................2
() 44 Short Rods.....................2
() 45 LongRods......................3
() 46 Wooden Push Rods........2
() 47 Shrink Tubing ...............4
() 48 Push Rod Exits..............3
() 49 Horizontal Stabilizer.....!
() 50Vertical Stabilizer .........1
() 51 Rudder............................1
() 52 Elevators.........................2
() 53Turtle Deck....................1
() 54Spinner...........................1
() 552 x 20mm Screws ..........6
() 56 Right Cowl.....................1
() 57 Left Cowl.......................1
() 58 Canopy...........................1
() 59Red Striping Decal........1
() 60Side Decal......................2
3.

WING ASSEMBLY
3Trialfitthe 7mm dowel rods intothe holes andbuttthemup
againstthe frontsparThey shouldbe positionedstraightinand
parallelto thewingroot Once satisfied withthe fit,epoxy them
inplace usingslow cure epoxy.
1.On both winghalves, make a mark exactly 1 from the wing root
on the leading edge
4.Next,usinga sandingblocksandthewingroots of bothwing
halves to ensurethatthey areperfectlyflatBe carefulnotto
change the dihedralangle of the root
2Drilla 7mmholeateachmarkMakesurethatyou drillstraight
in at thecenterofthemarkparallelto thewingroot
5Trim eachwinghalffortheaileronservo as shownIt's much
easier to do thisnow thanafterthe wingis assembled
4.

IMPORTANT! The following two steps are critical in the assembly
ofthiskit.Iftheyarenot donecorrectly,wingfailurecould result Be
sure to use plentyof slowcure(30 min) epoxy
6 Check the wing joiner to find the angledsides Place the joineron
aflatsurfaceandrock untilyouhaveidentifiedthetwo angled
sides The angled face side should point forward and the angled
narrow side shouldfacedownforproperdihedralUsingoneof
the wingpanelstrialfitthewingjoinerandcheck forproper
alignmentPosition the joinerso it will be centered when the two
winghalvesarejoinedtogether Once satisfiedwiththe fit,glue
thejoinerinplaceusingslow cure epoxy Let cure
7Trial fitthe two halvestogether and lineupthe leading and
trailingedges Check fora goodgap-free fitSand ifneeded
Once satisfied,gluethetwowinghalvestogether usingslow cure
epoxy You can tapethe winghalves together to hold them tight
whilethe glue cures
9Install the wingcenter cover usingPlastizapCA Glue Wipe
off anyexcessglue immediately Nexton the front ofthe
cover glue the wingpadon as shownusingPlaslizapCA Glue
10Installthesix aileron hingesintothe slots at the trailingedge of
the wingusingepoxy Onlya smallamountof glue isneeded
here Use too muchandit will seep into the hinge causing itto
lock upYou maywishto applya smallamountofvasilineto the
hingejointto pr otect itagainst epoxy If any glue does set up into
thejoint,removeitimmediatelyusinga softclothandrubbing
alcohol.
8Lineupthereinforcementblocks as shownsothatthesides angle
in Remove thewingcoveringunderneaththe blocks Next, glue
the blocks tothe wingusing epoxy
11Applyepoxy to thecontiolrodsandinthecontrolrodslotsof the
aileronsNextputa smallamountof epoxy onto the the hinges
and install both ailerons
5.

12.Check the ailerons for smooth operation. By exercising the
aileronsaftertheglue is cured,you can loosen anyof the stiffness
thatmighthave been created by glueseeping intothe hinges.
15.Glue the three wing mountingblocks together using slowcure
epoxy. Center the threeblocks together by liningupthe holes.
The larger block shouldbe at thebottom.
13.Align theaileronservo trayon thewingandtrace arounditusing
aballpointpen.Remove the covering materialthatwas outlined
underneath the tray.
16.Install the blindnutsto thelarger side of the mounting block.
These caneasilybe pressed inwitha pairof pliers.
14.Glue the tray tothe wing using slowcure epoxy.
17. Epoxy the mountingblock inside the fuselage. It is critical that
this joint is solid. Use plenty of epoxy. Let cure.
6.

18.Thread the wingscrews into the blocks sothat the heads are 3/8"
above the block.Applyinkor paintto theheads ofthe screws.
Proceed withthe next step immediatelybefore theinkor paint
dries.
21.Place the two 4mm washers onto the 4 x 30mm screws and push
themthroughthewingfrom the bottom side. Next, slide the
rubber 0-rings onto the screws.
19.Place thewingontothefuselage as shown.Put the frontinfirst
by insertingthe dowel rods intheholes. Itmaybe necessary to
roundthetipsofthe dowelrods andbevel theholes inorder to
alloweasier installation.Once inplace, centerandlowerthe
back onto the screwheads. This willmark where you need to
drill.
22. Trialfitthe wing onto the fuselage. Check for a solid fitthen
remove.
LANDING GEAR INSTALLATION
20.Drilltwo 3/16"holes 90°from the bottomwing surface using the
paintmarksas a guide.
7.

1.Feelalong the frontedge ofthe bluestripe untilyou findthe two
slotsunder the covering, trimout the covering over the slots.
4.Temporarily install the strut and mark the bottom ofthe fuselage
for the installationof the control rod Markthe hole about 1"
from the firewalland7/8fromtheleftbideof thefuselage.
2.Installthetwo maingear strutsintothewingandattachusing
the plasticretainingstrapsand3 x 10mm self-tappingscrews.
You maywithto drilleight1/16"holes toprevent the wood from
splittingwheninstallingthescrews.
5.Drill a 1/8"hole angling back at the mark.
Attach the bellcrankonto the front gear strut andsecurewith a
3x 8mm screw ontotheflat.6.Epoxy inthe whitetube sothatitonlyprotrudes 1/8"out ofthe
fuselageMakesureallexposed wood aroundthe tube iscovered
withglue inorder toseal against fuel.
8.

7.Make a Z-bendon one end ofthe450mm control rod. Install the
frontstrut with the rod and secure with a collar and a 3 x 5mm
screw.
1.Temporarily install thetwo mountingplates onto the mountso
the engine willangleslightlyto therightfor2 degrees. Tighten
the screws onlyuntiltheyseat sothatyou can still move the
plates.
8.Installthewheels usinga wheelcollaron each side ofthe wheel.
Fasten the collars with 3 x 5mm screws. 2.Settheengineon themountingplates sothatthecenter lineof
the engineis inlinewiththecenteroftheengine mount.Make
sure thatthe engine hasa slightrightthrustangleof 1 or 2
degrees andthatthefrontofthedrivewasher on theengine is
4-5/8"fromthefirewallNext,squeeze theplatesagainst the
engine and mark the mounting holes on the plates.
EngineInstallation
9
3.Remove the plates anddrill four1/8"holes at the marks.
Carefullyremove offanyburrswitha hobby knife.

4. Mount the engineto themountingplates usingfour3 x 15mm
screws, fourlock washers,andfour3mm nutsas shown.Note:
Usethread locking compound on the screws and nutsto
prevent them from loosening under vibration.
7.Install the throttle control rod on the throttle arm ofthe engine.
5.Epoxy the white tube into the fuselage sothat it sticksout I".
8.Slide thethrottlecontrolrod intothe whitetubeandattachthe
engine to themount.Use four3 x 15mm screws andfourlock
washers to holdtheengineinplace. Note:Usethread locking
compoundonthescrews.
Fuel tankAssembly
6.Make a Z-bend in the 450mm rodasshown
10.

1.Install one ofthe long and one ofthe short fuelpipes through the
rubbercap. Centerthepipesinthecapandplacethetwoplastic
discs ontoeach side.The large one shouldbe on theoutside.The
flangeon thesmalloneshouldface therubbercap. Putthe3 x
18mmself-tappingscrew inthecenterholefrom the large end
andtightenitonlya coupleofturnsintothesmalldisc.
4.Attach the completed fueltankcap to the tank.Make sure that
the bentpipeis pointingto thetop.Slidethecapon untilthelip
on thefueltankis inthegroove of thecap. Thentightenthe
screw. Check to makesure the clunk isfree toswing at the
bottom of the tank.
5.Gluetheneopreneringto thetankwithsiliconesealer. Attach
two pieces of fueltubing(5"long)to each of thepipes.
Attach thefuellineto theshort fuelpipeandattachtheclunkto
the otherend.Adjustthelengthof thelinesothattheclunk
reaches nearlyto the rearof thetankbutnot upagainst itonce
installed.
Carefully bend the other fuel pipe soit will just touch the inside
top ofthe fuel tank
6.Put a bead ofsilicone sealer on the ring. Proceedwith the next
step beforethesealerdries.
11.

8.Install the completed tankinto the fuselage. Route the fuel
tubingthroughthehole andpush thetankcapthroughuntil
seated. Attachthe carburetor line(bottomone)to the engine.
Shorten as needed.
Radio Installation
2.Screwthe aileron horns onto the aileron arms.Make sure you use
the two horns with the larger holes.
3.Cut five3/16"pieces ofthe clevis retaining tubing. You will use
twonowandthree later.
1.Check the fitofyouraileronservo inthe aileronservo tray.You
mayhave to trimawaysome ofthe servo tray fora goodfit.
Installthegrommets ontotheservo and mountusing the screws
provided withthe radio system.
4.Screw two snap clevises halfwayupthethreadson theshorter
controlrods. Next,slidetwoofthe3/16"clevisretainingtubes
onto the rods.
12.

5.Attach the clevises to the aileronhorns and slide onthe retaining
tubes. Aftercheckingtheneutralpositionoftheaileronservo
and ailerons,puta markon thepushrods (scratchingwitha
hobby knife)wheretheservo armholes line up. Besure the
aileronsare inthere neutralposition.
8.Connect the aileron servoto the receiver and check the movement
of theailerons.Make sure thatboth ailerons are neutralwhen
the servo is neutral.Adjust the clevises as needed.
6.At each mark,bendthepushrodsat a right angle. Next, cut off
the pushrods 6mm from the bend. 9.Installthe threeremainingservos intothe trayusingthe
grommets andscrews providedwiththe radiosystem. Be sure
thattheservos are positionedas shown. You may have totrim
the tray slightly for a perfect fit.
7.Attach the rods to the servo armusingtherod clevis. Installthe
clevis fromthe undersideof theservo hornthensnaponto the
rod.
10.Installtheswitchintothetray. You willhaveto drillthe two
mountingholes dependingon the switch.For a cleanerlook,
install the Dubro #203 Kwik-Switch mount.
13.

11.Bend the three long rods asshown for the elevator and rudder.
Note: the pre-bent rodswill beused later in step 13.14.Next, do the same with the rudder push rod. Make sure thateach
rod fitsinthegroove Now slidethefourpieces of shrinktubing
over theendsofthe woodenrods andshrinkthemwitha heat
gun or lighterTo ensuredurability,placea dropor twoof
Cyanoacrylateglueon theedges of theshrinktubing
12Drilla 1/16"hole1 1/2"from theends(2holes 1/16"aparton one
end of onerod)of both wood pushrods Witha hobby knife,
carefullycutstraightgrooves fromtheholesto theendsOnly
cut a groove on one side of each end,except fortheend ofthe rod
with two holes. Forthis end, make a groove on both sides.
15.Trim outthe three push rod exitsat the tailandinsertthe
rudderandelevatorpushrodsintothefuselagefromthefront.It
may benecessary to bend the rods slightly for a perfect fit.
13.Assemble theelevator pushrod as shown. Place the two elevator
rods intothedoublegrooved end oftherod Next,place one of
the short (pre-bend) rods into the other end.
16.Using PlastiZap, glue the three plastic push rod exits to the
fuselage Check to makesure thattherods willeasilymove in
andout withno resistance. You may have to bend the rods
slightlyforperfectfit
14.

17.Slide the throttlerod throughanE-Z Connector and attach to the
servo arm.Withthethrottleat lowposition,pullback therod
andtightenthescrew on theconnector.Plugthethrottleservo
intothereceiverandcheck forproperoperation.
1.Trim out the covering and the wood pieceat the tailofthe plane.
18.
Slide thenose wheelrod throughanE-Z Connectorandattachto
the servo arm.Withtherudderservo at centerposition,center
the nose wheelstraightandtightenthescrew on theconnector.
Plug therudder servo intothe receiver and check for proper
operation.
2.Temporarilyinstallthe wing.Next,place thehorizontal
stabilizerinplace.Visuallyinspect thewingandstabilizerto see
iftheyare parallel.Ifnot,sandthehigherside ofthestabilizer
mountuntilthestabilizeris parallel.Itis criticalfor proper
performance that these two surfaces are parallel.Take
extratime toensurea correctfit.
TailAssembly
15
3.Next, takea piece of stringandattachitwitha pinto thetop
center ofthefuselage. Makesurethatthestabilizeris centered
and stretch thestringto thecorneroftheelevator. Adjustthe
positioningofthestabilizersothatbothcorners arethe same
length whenmoving the string from side to side.

4.When thestabilizeris perfect, draw a linewitha sharp pencil on
both sides top andbottom (4linestotal).
7.Measure the rear fuselage tofindthe center. Draw a line along
center.
5.Remove the covering between the lines using a hobby knife.8.Applyslow cureepoxy to thelineandthe bottom ofthevertical
finandinstallthe verticalfin.Lineupthefinwiththe rear of
the fuselageandthecenter line.Temporarilyinstalltheturtle
deck as a guide forthefin.Checkthefinusinga 90°angle to
ensure thatit isstraight upand down. Letcure.
6.Using slow cureepoxy,gluethestabilizerinplaceapplyingglue
totheexposedwood areas. Recheck thealignmentusingthe
string as done earlierinstep 3.Wipe offany excessglue using a
soft cloth andrubbing alcohol.
9.Wrapthebattery andreceiverinfoam andinstall.Place the
batteryabove thefueltankandthereceiverbehindthefueltank.
Makesure thattheradiois hooked upcorrectly and that an
aileron extension isbeing used.
16.

10Trial fitthe turtledeck onto the fuselage and check for a goodfit
Once satisfiedwiththefitattachtheturtledeck to thefuselage
using PlastizapCA glue Be carefulnotto use to muchglue
13Glue on the control surfaces with slow cure epoxy and allow to
cure Checktheoperationoftheelevatorandtherudderto
ensure smooth performanceIfthey seem stiff,continueto
exerciseuntil they loosenup
11TrialfittherudderontotheverticalfinNoticewhere thebottom
hingemeetsthefuselageandmarka spot inthefuselage where
the rudderhinge slot willneed tobeusing a hobby knife
14Positionthecontrolhornson the elevators and mark the holes for
each ontothesurface
12Using slow cure epoxy, glue the seven hinges intothe elevator
halvesandtherudderDo not use too muchglueor youmayglue
the hingejointsolid
15Position thecontrolhornon the rudder andmarkthe holes onto
thissurface
17

16.Drillsix 1/16"holes at the marks.Make sure todrill straight in
throughto theotherside andmountthethreehornsto the
surfaceswiththe 2 x 20mm screws. Pass the screws throughthe
horn,throughthe surface and finallythread them into the
backplates.
19.Align the control rods over the respective servohorns andmakea
markwherethey intersect.Makesurethatthecontrol surfaces
are in neutral(center position) before marking.
17.Slide one of theretainingtubes ontoeach rod. Screw on the
plastic snapclevises to the threepushrods comingoutof the
fuselage. Screwthem on halfway up the threads.
20. Next,makea 90° bend upwardsat themarkandcutoff the
excess sothatthere is only6mm of rod afterthebend.
18.Attach therespective control rods to each horn.Use the middle
hole of thehorn.Makesurethatboth elevatorsurfacesare the
same. You will haveto adjust the clevises to equalize. Next, slide
upthe retainingtubes to lock the clevises.
21.Attach therods to the servos usingthe rod clevises as shown in
the above picture.You mayneed to enlargethe holes inthe
hornsslightlyfora goodfit.Check to ensurethatwhenright
rudderis given,thenose wheelalsoturnsright.Ifnot,simply
install the E-Z Connector on the other side of theservo arm.
18.

Cowl Installation
3Position the cowl inplace anddrilltwo 2mmholes 1 1/2apart on
each sideandinstallthe2 5 x 10mm S/Tscrewsto secure the
cowl inplace Attachthemufflerandpressureline
1Lightlysandtheflangeson theleftandrightcowl edges This
willallowtheglueto adherebetterto theplasticNextholdor
tapetherightside overtheflangeof theleftside andglue
together alongtheinsidebeam withPlastizapCA glueLet cure
Final Assembly
2Trial fitthecowl over the engine You willhave to trimslightly
to allowclearancefortheneedlevalveandmuffler1Using Plastizap CA glue the canopy ontothe fuselage and apply
theredstripingdecalaroundtheperimeter
19

2.Next, carefully apply the decals tothe cowl and the turtle deck.
Usethe box lidfora reference. 5.Route the antenna through the hole in the fuselage and through
the hole inthe tail. Usethe plastic retainer and secure the wire
tothe tail.
3.Installthespinnerback plate,prop, prop washer, prop nut and
spinnerwiththe 2.5 x 12mm S/Tscrews.
CENTEROFGRAVITY
4. Drill two 1/16"holes for theantenna.Position the first hole in
the leftside of thefuselage andthesecond holeat thetop of the
vertical fin.
Measure back 4-1/4" to 4-1/2"from the leading edge of
the wingnext to the fuselage. Balancetheplaneat this
point. If not, add weight to the nose or the tail until it
balances perfectly. Seebelow.
The centerof gravityis a veryimportantaspectof
setting upan airplaneproperly.Itwillcontrol a large
partof whattypeof flyingcharacteristicsyourplane
willhave.If it is nose heavytheairplanewilltryto
dive,andtheelevatorwillbe sluggishto respondto
your control inputs.If the planeis tailheavy,it will be
verysensitivetotheelevatorandpossibly
uncontrollable.The center of gravity shouldbe checked
withthefueltankemptyandwithradioequipment
installed.Theplaneshouldbalancewithin4-1/4" to
4-1/2"back fromtheleadingedge at the fuselage.If it
does notbalancewithinthisrange,add weightto the
noseor tail as you need to obtain the proper balance.
20.