Hobby-Lobby Telemaster 40 Deluxe User manual

Telemaster 40 Deluxe
MADE IN THE USA
Assembly Manual
Hobby Lobby International
5614 Franklin Pike Circle
Brentwood TN 37027 USA
Phone [phone]

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

Your Telemaster kit can be constructed with several options. You can build it as a standard gear (tail
dragger), the classic Telemaster stance or a more modern tricycle gear model. You can also build
either of these to accommodate the Telemaster Float kit for operation off of water. As you progress
through the assembly procedures we will point out the various deviations from the basic standard
gear conguration.
FUSELAGE ASSEMBLY
c 1
c 2
Assembling the registration pins.
We will be using two types of pins; regis-
tration pins and push pins. Registration
pins are assembled from two ber blocks
and two specially prepared 2-1/2” nails.
Push pins will be used to temporarily se-
cure parts to the building board.
Locate the two pinning blocks supplied.
Note that they have a counter sink on one
side. This is the side that the nail must be
inserted from. Place the block on a piece
of scrap wood to prevent the ber block
from tearing out when the nail is driven
through. Now hammer the nail through
just far enough to exit the block. Next
place the block up against the side of the
bench or other heavy object and nish in-
stalling the nail. When done, the nail head
should be in the recess so the block can
sit at on the bench. Repeat this process
with the second pinning block assembly.
Locate the rewall sections, FW-A and
FW-B. Place FW-B on the registration
pins. Test t FW-A; make sure you have
the correct orientation so the holes line
up. Apply thick CA to FW-B and then in-
stall FW-A with the labeled side up.
Install four #6-32 blind nuts in the holes
provided from the FW-B side.
Assembly of the rewall is underway. FW-B has been installed
on the pins and now glue will be applied to the top of FW-B and
then FW-A will be installed on the pins and pressed into contact
with FW-B.
2
NOTE: The bolt pattern on the rewall will
t the Hobby Lobby 40 size glow motor
mount Cat #MT11022 as well as the elec-
tric motor mount supplied.

c 3
3
TRIKE VERSION ONLY
A. Locate NGNP and install four #4-40
blind nuts.
B. Install and glue three NGMB into FW-A
in the slots provided. Use Epoxy or PU
glue for this.
C. Install and glue NGNP to the three
NGMB parts, the blind nuts should be on
the side facing FW-A.
ABOVE: Three nose gear mounting brackets (NGMB) are be-
ing installed into the rewall assembly. BELOW: The nose gear
nut plate NGNP has been installed onto the three nose gear
mounting brackets and the nylon nose gear bearing has been
installed.
c 4The fuselage sides are supplied in two
sections, FS-A and FS-B, they are joined
by a nger joint at the front. Place the
parts over a piece of parchment paper
and apply thin CA. Wipe off any excess
glue and sand out any bumps.
ABOVE: A straight edge is being used to force
the two fuselage sections at against the building
board while thin CA is being applied.
BELOW: The nished nger joint.

4
c 8
c 7
c 6
c 5
We will now start the fuselage side sub-
assemblies; make sure you make a left
and a right side. Place one of the fuse-
lage sides on the registration pins using
holes A and D. Slide FD down the pins to
test t. When satised with the t, remove
FD and apply thick CA to the back (the
side facing the FS assembly) and then
reinstall it onto the pins and slide it into
contact with the FS assembly. Apply even
pressure until the CA has cured. Repeat
this process for the remaining side and
remember to make it a mirror image of the
side you just created.
If you are building the trike version, re-
move the dash cut material by register pin
holes G and H.
Next we will install the mains landing gear
brace (GB). If your are building the stan-
dard gear version (tail dragger) install the
register pins in holes E and F and install
GB. If you building the trike version, in-
stall the register pins in holes G and H
and install GB
Place the register pins in holes B and C
and install and glue the fuselage wing
saddle (FWS).
ABOVE: The right fuselage side with a registration pin inserted
in holes A and D ready to install the doubler FD.
BELOW: With the registration pins inserted in holes G and H,
the gear brace for the trike version is being installed.

5
c 12
c 10
c 9Locate four ¼” x ¼” x 36” sticks, they will
be glued into each corner of the fuselage
aft section. Start with one stick butted up
against FD. Note that the stick must be
glued in line with the inner notches. This
stick will terminate at and to include F9.
ABOVE: The 1/4” square corner stringers are being installed.
One of the pinning blocks is being used to align the stringer
with the edge of the fuselage side.
Install the top corner stringer starting at
the back of FWS and terminating at and
to include F9.
c 11 If you plan to use oats you will need to
install the oat hard point. Remove the
dash cut material just behind F4, includ-
ing a notch in the ¼” square stringer.
Assemble F2 from two 1/8” ply sections
using the register pins.
ABOVE: F2 is being assembled on the registration pins, thick
CA is used to laminate the two parts.

6
c 16
c 15
c 14 The rst glue up of the fuselage will con-
sist of the rewall assembly FW-A&B, the
fuselage oor FF, the F2 assembly, F3,
F4, the wing bolt plate FWBP, the hatch
mounting plate FHMP and the servo tray
FST. Use a slow curing adhesive such
as aliphatic resin to allow time to work.
Glue each part and install it into the right
side. Next apply glue to the left side of all
these components and install the left side.
Place a at board or other object on this
assembly until it has cured. Make sure all
tabs are bottomed in the notches and all
components t ush to both sides. ABOVE: Joining the fuselage side assemblies begins by install-
ing formers, the fuselage oor, wing bolt plate and the forward
hatch mounting plate in one side and then applying glue to the
top side of these components and installing the remaining fuse-
lage side. In the photo, the wing bolt plate and the forward hatch
mounting plate remain to be installed.
Before pulling the tail section together we
need to pre-assemble F9 with FTGM and
F8 with SMP. Use your square to assure
that these components are at 90º to each
other.
ABOVE: The fuselage tail gear mount (FTGM) has been joined
with F9 and the stabilizer mounting plate (SMP) has been
joined with F8
Install the F8 and F9 assemblies at the
same time. Apply glue to both sides of
these assemblies and install. Pulling the
tail section together. It is very important
that these parts be completely inserted
into their respective notches to assure the
stabilizer mount will be level. Use clamps,
tape or rubber bands to assure these
parts t tightly.
c 13 Install two 1/4” x 20 blind nuts into
FWBP.

c 19
c 18
c 17
c 20
7
Install and glue F5, F6 and F7. Install
each former into the notches on one side
and then tip into the other side.
Using the registration pins, assemble
the landing gear mount from LGM-A and
LGM-B. Install four #6-32 blind nuts from
the LGM-A side and install and glue it into
the fuselage side at GB. Remember this
can be positioned at one of two locations,
forward for standard gear and aft for trike
gear.
BELOW: The landing gear assembly is ready to be installed
into the fuselage. The word UP refers to its position in the fuse-
lage, the nuts must be facing the inside of the fuselage.
If you have opted to install the oat hard
point, now is the time to install it. Assem-
ble FAM-A and FAM-B using the register
pins. Install four #6-32 blind nuts from the
FAM-A side. Install and glue it at the loca-
tion indicated just aft of F4.
Install one ¼”magnet into the hole in
FHMP, this will be part of the hatch hold
down system. Make the magnet ush
with the top of FHMP so the hatch can
t tightly.

8
Place the remaining magnet near the one
installed in FHMP and let them join. Mark
the top of the top magnet with a magic
marker. Locate the hatch components
FHA and two FHA-H. Place the FHA on
the bench with the labeled side down and
install the remaining magnet in the hole
provided with the side you just marked
facing down. With the labeled side still
facing down, install the two FHA-H rail
hooks.
c 21
c 22
c 23
Install and glue the 4” length of 3/8” tri-
angle stock in the notch provided at the
base of the windshield. The wide side of
the triangle stock will be perpendicular to
FHMP.
Install and glue WS, note that a small
chamfer must be planed into it at the top
where it contacts F2.
ABOVE: 3/8” Triangle stock installed.
Below: Windshield (WS) has been added.

9
c 25
c 26
c 28
c 29
c 27
c 24 Place the hatch cover assembly onto the
fuselage and install and glue the ¾” x 4”
triangle stock onto the hatch cover. This
should butt snugly up against the 3/8” tri-
angle stock installed in step 21.
Install and glue the top turtle deck FTD.
Use clamps or masking tape to pull the
sides snugly against FTD. Start at the tail
section and work forward.
If you are building the trike version, install
LG-PLUG assembly in the notch where
the main gear would have gone. This as-
sembly consists of LG-PLUG-A and LG-
PLUG-B and assembles just like the LG
assembly did.
BELOW: Clamps and tape secure the sides tightly to the top as
the adhesive cures, use this same method when installing the
fuselage bottom.
Next we will install the fuselage bottom
FB. Note the two dash cut sections in
FB, if your building the standard version
both of these will remain intact. If you
are building the trike version, the forward
most dash cut area must be removed to
accommodate the gear mounting assem-
bly LGM-B. If you are using the oat hard
point you will need to remove the aft most
dash cut area.
Install and glue one FA to the forward bot-
tom fuselage section just behind the re-
wall on each side.
Assemble the forward bottom sheeting
BS-A and BS-B and glue it into position
between the rewall and LGM.
ABOVE: Mount for the trike mains on the left and on the right
for the optional oat kit.
BELOW: The forward bottom sheeting BS-A and BS-B has
been installed.

10
Install and glue the nose ller pieces NF.
c 30
c 32
c 31 If you are building the trike version, now is
a good time to install and adjust the nose
gear steering cable. Note that a ball link is
used on the steering tiller arm.
Locate and prepare the ve electric mo-
tor mount parts, MMA, MMB, MMH, MMV
and MMBP. Use Epoxy to or PU to as-
semble these components. Note that the
bolt pattern on the motor mount bolt plate
(MMBP) is the same as that used on the
Hobby Lobby 40 sized glow motor mount
catalog # MT11022. Use the pinning
system to assemble the laminated parts
MMA and MMB. Install MMH and MMV in
the bolt plate MMBP. Next glue the MMA/
MMB assembly to MMH and MMV.
Install the motor mount with four #6-32 X
3/8” socket head bolts and at washers.
c 33
This concludes the basic fuselage assembly. You will want to install all radio gear and control
linkages before covering the model. Once covered you will not have access to some parts of the
model.

11
c 1
STABILIZER ASSEMBLY
Cover the stabilizer plans with parchment
or waxed paper. Prepare the stabilizer
plate (SP). Install four #4-40 blind nuts
into the holes provided. They should be
installed from the top. Pin this part in place
over the plans. Place the pins through the
blind nuts to keep them out of the way.
c 2Iinstall the stabilizer false leading edge
(SFLE). Position the tab on SP into the
notch in SFLE and glue.
c 3Install the stabilizer 1/8” X 1/2” basswood
bottom spar. Place into the notches pro-
vided on either side of SP and glue it in
place. Align the outer ends of tn
he spar with the plans and pin in place
with push pins.
c 4Install and glue the false trailing edge
(SFTE) to the aft edge of SP. The center
notch will position it correctly.
c 5install and glue two S1 ribs in the notches
provided.
c 6install but do not glue two stabilizer sheer
webs (SSW). These will remain loose un-
til all the ribs have been installed.
c 7install but do not glue all remaining stabi-
lizer ribs, S2 through S6.
c 8Before gluing the assembly this far, make
sure the bottom spars are aligned with
the plans. Begin by gluing each rib and
sheer web to the bottom spar. Make sure
each rib is bottomed in the sheer web
slot. Then glue the false leading and false
trailing edges to each rib.
c 9install the stabilizer tips (SWT). They
should butt against S6 and against FLE,
FTE and SW. Glue these into position.

12
c 12
c 10
c 11 Note that at the center of the false trail-
ing edge and false leading edge there is
a low spot. This is to accommodate the
center section sheeting. Before installing
it you will need to sand the top of the false
trailing edge and the false leading ush to
and at the same angle as the ribs.
Install and glue the center section top
sheeting sections SCS-A and SCS-F. Af-
ter the glue has cured, remove the dash
cut material in the center to allow for in-
stallation of the vertical n.
Install the top spar from 1/8” X 1/2”
basswood stock. Taper the ends to butt
t to the stabilizer tips SWT. When your
satised with the t of this bevel, glue the
top spar into position.

13
c 2
c 1
c 13 Install and glue the trailing edge STE. The center notch will determine position.
c 14 Install and glue the leading edge SLE. The center notch will determine position.
c 15 Use a plane and sanding bar to shape the leading and trailing edges of the stabilizer. Sand all
surfaces as required in preparation for covering.
c 16 Use a hobby knife to continue the hinge slots TE into the false trailing edge SGTE.
Locate the shaped elevator. Note that the
two elevators are connected by a web at
the center. Keep this web in place until af-
ter installing the elevator joiner parts EJ-A
and EJ-B. Place the trailing edge against
a straight edge and pin to the workbench.
Then install and glue EJ-A and EJ-B. Note
that the elevator horn will attach to EJ-A
on the elevator half.
Sand the joiner to contour with the lead-
ing edge and then sand the taper at each
end to match that of the stabilizer.
This completes the assembly of the stabilizer.
Elevator assembly.
This concludes the elevator assembly.
c 1Prepare all rudder components, R1, R2,
R3-A and two R3-B. Glue R2 to R1; note
the correct orientation. The end of R2
marked TOP should be toward the tip of
the rudder. After installing it, trim the bot-
tom to match the angle of the stabilizer
opening in R1.
Rudder assembly
c 2R3-A is laminated between too R3-B parts
to form both the rudder horn mount and
also provide a slot for the tail wheel arm.
This will allow the empennage assembly
to be removed easily. Glue R3-B to R3-
A, then ip the assembly over and glue
the remaining R3-B to R3-A. Glue this as-
sembly into the notch provided in R1.

14
c 22
c 1
Sand the rudder assembly at and then
round off the trailing edge. Extend the
hinge slots into R1 and slightly bevel both
sides of the assembly to allow for move-
ment when installed.
This concludes the rudder assembly
Vertical Fin assembly
c 3Glue V4 to the V1, V2 and V3 assembly.
c 4Install and glue the cross members, V6 and V7.
c 5Install and glue the trailing edge piece V5, Note the correct orientation of V5. The end marked
TOP should be at the tip of the vertical n.
c 6Trim the bottom of V5 to align with the opening in V1.
c 7Sand this assembly at, Note that the leading edge will be rounded later after you can mark the
location where the dorsal n VF intersects with it. Extend the hing slots into V4.
This completes the vertical n assembly.
Wing joiner platform assembly
Locate and prepare the wing platform
WP. Note that the wing platform is not
built over the plans.
c 2Use the registration pin system to install
WP-F at the aft end of WP.
c 3The wing joiner WJ, must be laminated
from two 3/32” ply parts. Use the regis-
ter pins to glue these two together to form
WJ. Place the parts back to back (label
out on both pieces) to neutralize any po-
tential warp.
c 4Glue the joiner assembly into WP, use
your square to assure that WJ is perfect-
ly perpendicular to WP. As shown in the
photo on the next page
c 1
c 2Glue V1 to V2 and then glue V3 to V2. Note that the vertical n assembly is self aligning and
need not be built over the plans.
Laminate the two V1 using the register pins.

15
c 14
c 5Install and glue WP-FLE to the leading
edge of WP.
c 6Use Epoxy or thick CA to install and glue
WP-1A to WJ, WP and WP-FLE.
c 7Install and glue WP-1B to WJ and WP.
c 8Install WP-B1 and WP-B2.
c 9Install and glue rib WP-2 on both sides
of SP.
c 10 Use one of your register pins to install and
glue one WP-DS to the inside of each W1
rib. These will support the 1/8” alignment
dowels we will install next.
c 11 Locate the 1/8” hardwood dowel. Use
sandpaper to round off both ends and then
cut the ends off to make two 3/8”lengths
with rounded ends. Glue the cut ends into
the holes at the aft end of the WP-2 ribs.
These will insure correct wing alignment
when assembling the wing panels.
c 12 Use a plane to remove the bulk of material
on WP-F to contour with the ribs in prepa-
ration for installing the top sheeting.
c 13 Plane or sand the false leading edge WP-
FLE to contour with the ribs.
Locate and assemble the platform top
sheeting sections CS-A, CS-B, CS-C and
CS-D. Place CS-Aon a piece of parchment
paper with the labeled side up. Butt CS-B
up against CS-A but with the labeled side
down on CS-B. Apply thin CA along the
joint and then immediately wipe up any
excess with a QUICK wipe with a paper
towel. Flip the piece over and wipe off any
excess CA on the parchment paper or the
back of the assembly. Continue with this
process until all sections are joined. By
ipping every other section over you are
improving the t between parts, there is a
very slight expansion of the kerf from top
to bottom and this technique eliminates
any gap. Determines the best side of this
assembly and sand it while still at on the
bench.

16
c 15 Use the register pins to position the top sheeting and glue it into position. Use tape or weights to
hold it in position until the adhesive has set.
c 16 Install and glue WP-LE into position on the leading edge.
c 17 Plane and sand LE to contour with the ribs.
This completes the assembly of the wing platform.
c 2
Test t but DO NOT Glue this assembly into the opening provided in WP. When installed correctly
it should t at on WP. Epoxy this permanently in position After covering the model.
c 19
Locate the wing hook parts, two WH-A and one WH-B. Use the register pins to laminate these
parts with one WH-A on either side of WH-B.
c 18
Wing assembly
Lay one of the wing plans on the bench and cover it with a piece of waxed paper. You will be
building the wing over the plans. If the plans are slightly out of size, do not be concerned. The
paper they are printed on will shrink and stretch with changes in humidity and temperature. The
parts will always determine the correct location of components so only use the plans to insure
alignment and location of parts. Place the plans with the leading edge of the wing away from the
edge of the bench you will be working from. We will begin by building the LEFT wing. Some of
the procedures will be reversed for the right wing.
c 1Locate and prepare one false leading
edge (FLE).
Align a straight edge with the aft edge of
FLE on the plans and secure it in this po-
sition with push pins.
c 3Place FLE in front of the straight edge,
note alignment lines at the front of W2 on
the plans. Align the notch in FLE with the
lines in front of W2 and use a pinning tab
to press FLE up against the straight edge.
Tack glue the pinning tab to FLE and then
secure the tab to the building board with
push pins.
c 4Moving down the wing, install a pinning
tab in the same manner at every other rib.
This will secure the false leading securely
to the building board and insure a straight
wing. Make sure it is at on the building
board.

17
c 5Prepare TE, TES and TESB. Note that the notches in TESB are 1/4” deep on one side and 3/16”
deep on the other. Place it on the bench with the 1/4” side facing you. Install and glue TES in the
front (3/16”) notches. It is best to place this up against a straight edge to insure that the assembly
will be straight.
c 6Install TE into the 1/4” notches facing you, this is the trailing edge sub-assembly.
c 7Prepare the top and bottom sheer webs
SW-T and SW-B. When preparing the
sheer webs, remove the small half el-
lipse shaped pieces at the root ends but
DO NOT remove the dash cut material
c 8Prepare two spar box caps SBC. We will
be gluing these to each sheer web in the
following steps. Lay the sheer webs on the
bench with the labeled side up. (NOTE:
When assembling the right wing you will
want these on the bench with the labeled
side down.) Place one SBC on the regis-
ter pins as shown in the same orientation
as SW-T. (Photo A) Slide SW-T down into
contact with SBC. Very lightly, tack glue
SW-T to SBC through the small half el-
lipse openings (Photo B). Tack glue to the
outside edge, NOT the inside edge. When
cured, carefully remove from the pins and
ip the assembly over. Glue SBC to SW-T
at the inboard end (Photo C) then ip the
assembly over with the labeled side up.
Carefully cut along the dash cut lines and
remove the internal section of balsa from
SW-T (Photo D). This will become the
socket for the wing joiner and is intention-
ally a snug t. If there is any material in-
side the pocket it must be removed now.
Glue SW-T and SBC along the entire in-
side line of the joiner opening.
A
Tack Glue Here
B
C
c 9Locate and prepare all wing ribs W1
through W12. Note that W1, W2 and W3
are two piece ribs.
c 10 Starting with W4 in the rst slot next to
SBC, slide each rib into the appropriate
notch in SW-B.

18
c 15
D
c 11 Slide SW-T down into the slots just be-
hind SW-B. Use nesse not force, when
everything is lined correctly they will fall
in place. IMPORTANT next we will tack
glue SW-T and SW-B together capturing
all ribs from W4 through W12 however it
is very important that SW-T and SW-B be
exactly aligned before applying glue. Use
nger pressure on top and bottom of the
sheer web assembly to assure they are
aligned and then glue them. Do not glue
the ribs. Use the glue ports (ellipses) cut
into each sheer web.
c 12 Place each rib into its respective slot in the
trailing edge subassembly, do not glue.
c 13 Slide the leading edge tab of each rib into
the appropriate notch in FLE. Carefully
check the alignment of the assembly and
then pin the trailing edge subassembly to
the building board.
c 14 This much of the wing assembly is now
ready fore some glue. Start with the lead-
ing edge making sure all parts are bot-
tomed in there notches in FLE.
Install and glue the two-piece ribs, W1,
W2 and W3.