Hobby-Lobby Mini Telemaster Aileron Wing Kit User manual

Mini Telemaster
Aileron Wing Kit
MADE IN THE USA
Hobby Lobby International
5614 Franklin Pike Circle
Brentwood TN 37027 USA
Phone [phone]
ASSEMBLY MANUAL
TEL12003

Terminology used in this manual.
With the precision of laser cut parts and notch and tab construction, the assembly and gluing sequence
becomes very important. If components are glued in place to soon, they will not allow enough move-
ment to install other components. When instructed to install a part, do only that. You will be instructed
to glue it when it is no longer required to be moveable.
Test Fit:
Test t and install but do not glue.
Install and glue:
Permanently install the part.
Locate and prepare:
Find the parts requested, you can locate them faster using the parts locator pages at the back of this
manual. The parts locator will direct you to the correct sheet number as well as describe the part for
easier identication. Most of the parts are supplied still in the sheet. These sheets are called the carrier
sheet and the parts are held in the carrier sheet by small breaks in the cutting line. These are called
retainer breaks and in most cases the parts can be extricated by simply exing the carrier sheet and the
retainer breaks will release the parts. In harder materials it may be necessary to use your hobby knife to
sever the retainer breaks to remove the parts. After removing the parts, a small nub may remain where
the retainer break was, this must be removed with a light swipe of sandpaper so it will not interfere with
the parts t.
Adhesives:
There are four primary types of adhesives recommended for constructing your model. They are Cyano-
Acrilate (referred to as CA) in all viscosities, Aliphatic Resin Glue (carpenters glue), Polyurethane glue
referred to as PU and Epoxy. CA is the primary adhesive to use however there are times when it is not
the best choice.
They are:
1. When you need more time to carefully position a part than a fast setting adhesive will allow.
2. When attaching plastic such as a windshield (Use Pacer formula 560 here).
3. When gluing laser cut aircraft grade plywood’s. The microwave set adhesives used in aircraft grade
plywood does not ablate well under a laser beam. As a result it burns the wood bers near by leaving
a charred edge. Fast setting CA adhesives do not allow time for the adhesive to penetrate this layer of
char and bond to the wood ber underneath. Use a slower setting adhesive such as Aliphatic Resin for
maximum strength use Epoxy on aircraft grade ply parts. Lite Ply’s do not use this type of adhesive and
do not suffer from this problem.
To apply thin CA we recommend the Dave Brown pipets available from Hobby Lobby. Be sure to stretch
the end (pull it with a pair of pliers) to a thin applicator tip, as they are not supplied in this congura-
tion.
1

c 4Glue the bottom sheeting part B to the trailing
edge of the bottom spar in the same manner as
the forward sheeting.
c 5Trim the sheeting and the bottom spar to the
plans at the root.
c 6Align the trailing edge assembly with the
plans and pin in place. Glue it to bottom sheet-
ing B.
c 7Glue WJP to W1; note the correct orientation
of WJP. WJP will determine the correct dihe-
dral angle of the root rib, W1. See photo B.
Wing Assembly
c 11. Assemble the trailing edge by gluing TE-A
to TE-B as shown in the photo. Note that
TE-B will stand proud of TE-A, this will be
addressed later.
c 2Pin the bottom spar, a 1/8” X 1/4” balsa stick
down to the plans in alignment with the draw-
ing. Let the stick extend at lease ½” on both
ends, this will be trimmed to t later.
c 3Glue the bottom sheeting part A down to the
leading edge of the bottom spar, carefully
align the inside edge to the plans and let any
excess protrude at the root and make sure it is
at on the bench.
2
3
4
6
PHOTO A
PHOTO B
2

Install but do not glue ribs W2 through W7
onto the bottom spar and the notches in the
trailing edge. You may notice that the plans
do not t the parts, do not be concerned. The
paper these plans are printed on may change
size depending on temperature and humidity.
The parts are correct so use the plans to align
the parts only.
c 11
c 10
c 9
Glue only W7 to the trailing edge (TE-A). In-
stall and glue the gusset (GU1) between W7
and TE-A. See photo D.
11. Install but do not glue the aileron bay trail-
ing edge (ABTE) into W7.
c 12 12. Lay the wing servo mounting plate (WSM) in position between ribs W7 and W8.
c 13 Install but do not glue the remaining ribs W8, W9 and W10.
c 14 Install but do not glue the leading edge. Adjust each rib to t into the notch provided in the leading edge.
Note that the notched side of the leading edge should be down. Sight down the leading edge and note that
all ribs look exactly the same.
c 15 IMPORTANT; in this step you will glue all the parts at the same time. It is important that you make sure
that each component is bottomed in the appropriate slot as well as making sure all ribs are at on the
building board. When all ribs are properly seated in their respective notches in the leading edge and trail-
ing edge, glue them to the leading edge, trailing edge, bottom spar and the ABTE. Also glue W2 and W3
to the bottom sheeting however do not glue the forward 1” of these two ribs. This will be done later after
trimming the sheeting to t the leading edge. Also center the servo mount evenly between W7 and W8 and
glue it to both ribs and the bottom spar.
3
c 8Carefully align W1 with the root end of the
plans and glue to bottom sheeting A, B and
the bottom spar. Make user WJP is at on the
building board. Do not glue the bottom for-
ward 1” of W1 to A, this will be glued to con-
form to the bottom of the rib after removal
from the plans. See photo C.
PHOTO C
PHOTO D
GU1

c 18
c 17
c 16 16. Install and glue a 1/8” sq. balsa in the
notches provided in the leading edge of each
rib. This will serve to stiffen the top sheeting.
PHOTO E
Glue a piece of 1/8” square scrap to each side
of the servo mount to help secure it to W7 and
W8. See photo E.
Trim the bottom spar ush with W10 at the
tip.
c 19 Install and glue the 1/8” x ¼” top spar. Trim
the top spar ush with W1 and W10
c 20 Glue sheer webs in each bay between the ribs
as indicated on the plans.
c 21 Install and glue the geodetic ribs G1 through G6 in each bay. Note that G1 has some material removed to
accommodate the sheeting. Sand a slight bevel on each end of these ribs to increase glue land and improve
the t. These ribs may have to be bowed slightly to install but should be straight after they are installed.
c 22 Install and glue the wing tip (WT) to rib W10. Use the gusset (WTGU) at the location of the spar to set the
correct angle. Glue a ½” piece of ½” triangle stock ller at the trailing edge and a ¾” piece of ½” triangle
stock at the leading edge.
c 24 Trim the bottom center section sheeting (A) to butt t to the leading edge and then glue it to W1, W2, W3
and the leading edge.
c 25 Shape the leading edge to contour with the ribs in preparation for installing the top leading edge sheeting.
Trim and sand W10 and the wing tip to match. Note that W10 is offset 1/32” aft of the spar to accommodate
the 1/32” tip sheeting. W1, W2 and W3 are also offset in this same manner so that after sheeting they will
be ush with the rest of the ribs.
c 26 Glue the top aft center section sheeting (D) on. Note that this sheeting should slightly overlap the top
spar.
Run a bead of thick CA down the top spar and
install the top leading edge sheeting. Glue it
only to the top spar at this time. Use a straight
edge to press the sheeting into contact with
the top spar.
c 28
c 29 Turn the assembly over. Apply enough me-
dium CA to the front of W2 until it runs down
the top of the rib as far back as the spar and
then hold the top sheeting into contact with
W2 until it cures. Apply thin CA to the lead-
ing edge and the top sheeting. Moving down
the wing from the root, glue the top sheeting
to each rib and the leading edge.
c30 Remove the dash cut material in W1 between the top and bottom spars.
This completes assembly of one wing panel, repeat steps 1 through 30 for the remaining wing panel.
4
c 23 Remove the wing assembly from the plans.
c 27 Plane or sand TE-B to contour with the trailing edge (TE-A) and the center sheeting.

c 1
Aileron Assembly
5
When assembling the ailerons, remember you
must construct a left and a right aileron. They
will be the mirror image of each other. It is
best to assemble both ailerons at the same
time to minimise the possibility of building
two the same. Place the aileron base (AB) on
the bench. Glue the 1/16” ply aileron horn
mount (AHM) into the notch provided.
c 2Glue the 1/4” balsa aileron leading edge
(ALE) to the aileron base. Remember to make
a left and a right.
c 3Install and glue the aileron ribs. Note that the
two end ribs (A1) are 1/8” balsa and the cen-
ter ribs (A2) are 1/16” balsa.
AB
Joining the wing halves
c 4
c 3
c 2
c 1Divide the 1/8” dowel into two equal pieces. Install each half into the holes provided in the wing hook
(WH). They should protrude at least a quarter inch on each side of WH.
Glue the wing hook to one of the wing panels with Epoxy.
Use a liberal amount of glue to install the wing joiner through WH and into the joiner box in the wing
panel.
Install and glue the remaining wing panel to this assembly. With one panel at on the bench, the dihedral
should be 1-1/2” at the raised tip.
1-1/2”
c 4Install and glue the aileron horn mount ll-
er block (AHMF) on top of the aileron horn
mount. Carefully align the slot in the block
with the slot in the mount plate.

6
c 6Install and glue the 3/8” triangle stock aileron
tips, then trim them to contour with the ribs.
This concludes the aileron assembly. The ai-
leron horns are installed permanently after the
ailerons have been covered. The ailerons are
attached wit tape hinges or you may prefer
making a hinge from your favorite covering.
IMPORTANT:
When setting up your ailerons, use differential throw for best results. Use 1” of up and 1/2” of down.
c 5Plane or sand the aileron leading edge to con-
tour with the ribs. Note that this will include
some material from the horn block.
ABOVE: Before and after contouring the leading edge and horn
block to the ribs.
LEFT RIGHT

Part # Qty Sheet # Material Size Usage
A 2 5 BALSA 1/32” X 3” X 36” Sheeting part A
A1 2 9 BALSA 1/8” X 1.5” X 4.25” Aileron rib #1
A3 2 2 BALSA 1/16” X 4” X 36” Aileron rib #3
A4 2 2 BALSA 1/16” X 4” X 36” Aileron rib #4
A4 2 9 BALSA 1/8” X 1.5” X 4.25” Aileron rib #4
AB 2 3 BALSA 1/16” X 4” X 36” Aileron base
ABTE 2 10 BALSA 3/16” X 1.5” X 8.3” Aileron bay trailing edge
AHM 2 1 PLY 1/16” X 3.2” X 4.2” Aileron horn mount
AHMF 2 7 BALSA 1/4” X 1.5” X 36” Aileron horn mount ller
AIL 2 1 PLY 1/16” X 3.2” X 4.2” Aileron horn
ALE 2 7 BALSA 1/4” X 1.5” X 36” Aileron leading edge
B 2 6 BALSA 1/32” X 4” X 36” Sheeting part B
D 2 6 BALSA 1/32” X 4” X 36” Sheeting part D
G1 2 3 BALSA 1/16” X 4” X 36” Gedetic rib 1
G2 2 3 BALSA 1/16” X 4” X 36” Gedetic rib 2
G3 2 3 BALSA 1/16” X 4” X 36” Gedetic rib 3
G4 2 3 BALSA 1/16” X 4” X 36” Gedetic rib 4
G5 2 3 BALSA 1/16” X 4” X 36” Gedetic rib 5
G6 2 3 BALSA 1/16” X 4” X 36” Gedetic rib 6
GU1 2 9 BALSA 1/8” X 1.5” X 4.25” Gusset #1
GU2 2 9 BALSA 1/8” X 1.5” X 4.25” Gusset #2
LE 2 7 BALSA 1/4” X 1.5” X 36” Leading edge
LES 1 6 BALSA 1/32” X 4” X 36” Leading edge sheeting
LES 1 6 BALSA 1/32” X 4” X 36” Leading edge sheeting
SHEER WEBS 16 5 BALSA 1/32” X 3” X 36” Sheer webs
TS 1 6 BALSA 1/32” X 4” X 36” Tip sheeting
TS 1 6 BALSA 1/32” X 4” X 36” Tip sheeting
W1 2 2 BALSA 1/16” X 4” X 36” Wing rib #1
W10 2 2 BALSA 1/16” X 4” X 36” Wing rib #10
W2 2 2 BALSA 1/16” X 4” X 36” Wing rib #2
W3 2 2 BALSA 1/16” X 4” X 36” Wing rib #3
W4 2 2 BALSA 1/16” X 4” X 36” Wing rib #4
W5 2 2 BALSA 1/16” X 4” X 36” Wing rib #5
W6 2 2 BALSA 1/16” X 4” X 36” Wing rib #6
W7 2 2 BALSA 1/16” X 4” X 36” Wing rib #7
W8 2 2 BALSA 1/16” X 4” X 36” Wing rib #8
W9 2 2 BALSA 1/16” X 4” X 36” Wing rib #9
WH 1 8 PLY 1/8” X 2.2” X 7.6” Wing hook
WJP 4 2 BALSA 1/16” X 4” X 36” Wing joiner pocket
WSM 2 1 PLY 1/16” X 3.2” X 4.2” Wing servo mount
WT 2 3 BALSA 1/16” X 4” X 36” Wing tip
7

Hobby Lobby International
5614 Franklin Pike Circle
Brentwood TN 37027 USA
Phone [phone]
TEL120003
Mini Aileron wing kit
Materials
Qty. Size Material
1 3/8" x 10" T.E. Stock Balsa
4 1/8" x 1/4" x 36" Balsa
2 1/8" x 1/8" x 36" Balsa
1 1/8" x 1" Dowel Hard Wood
1 Assembly Manual
1 .047" x 8" Music Wire
2 EZ Connector Micro hardware
3 EZ Link Micro hardware
Sheet # Laser Cut Material Size
1 PLY 1/16" X 3.2" X 4.2"
2 BALSA 1/16" X 4" X 36"
3 BALSA 1/16" X 4" X 36"
5 BALSA 1/32" X 3" X 36"
5 BALSA 1/32" X 3" X 36"
6 BALSA 1/32" X 4" X 36"
7 BALSA 1/4" X 1.5" X 36"
8 PLY 1/8" X 2.2" X 7.6"
9 BALSA 1/8" X 1.5" X 4.25"
10 BALSA 3/16" X 1.5" X 8.3"
Kit inventory check off sheet