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.