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Know your model’s parts.

Take a moment now to
match the box
contents with the items
listed below. Following
the SuperStar 40’s
assembly instructions
will be quite easy if you
identify and organize
the parts before you
begin. You may also
want to review the
glossary of special
modeling terms
included at the back of
this manual. Words in
your instructions that
appear in bold italic
type are explained in
this section.

Replacement Parts Available

Y

ou’re about to build in just days what took aviation

pioneers years—a powered machine that flies. Specially
created for you and other first-time radio control
modelers, Hobbico’s SuperStar 40 offers nearly all the
excitement of piloting a real airplane...and develops
skills that will take you anywhere you want in your new
hobby.

HCAA3065

Wing Kit

HCAA3066

Fuselage Kit

HCAA3067

Fin Set

HCAA3068

Landing Gear Set

* Parts marked with an asterisk are found on the plastic parts tree.

2

Landing Gear

Part #

Quantity

Main landing gear wires ............2
Nose gear wire............................1
Nose gear control horn..............1
*Landing gear straps..................2
Wheels ........................................3
Wheel collars w/ set screws ......5
3mm x 10mm wood screws.......4

Wing Assembly

Part #

Quantity

Right wing .................................................1
Left wing.....................................................1
Hinges ......................................................11
Plywood wing joiner plates ......................3
Ailerons (left and right).............................2
Wing center section tape ..........................1
Aileron servo tray ......................................1
Aileron servo tray mounting blocks.........2
*Aileron control horns ..............................2
Aileron pushrods.......................................2
*Clevises .....................................................5
Clevis safety tubing ...................................1
Wing alignment peg ..................................1

32

27

29

47

24

23

25

28

49

22

21

19

7

Tail Assembly

Part #

Quantity

Horizontal Stab and elevator ........1
Vertical fin and rudder...................1
Hinges ..........................................11
*Clevises..........................................5
*Control horns................................2
Pushrods .........................................2
2mm x 15 mm machine screws.....4

36

46

28

25

26

1

2

6

7

9

19

21

22

4

5

6

25

26

36

46

10

11

27

29

31

32

47

23

24

25

28

49

10

11

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Summary of Contents for Awarf Series

Page 1: ...Easy as 1 2 3 V1 3 Copyright 1998 ...

Page 2: ...want in your new hobby HCAA3065 Wing Kit HCAA3066 Fuselage Kit HCAA3067 Fin Set HCAA3068 Landing Gear Set Parts marked with an asterisk are found on the plastic parts tree 2 Landing Gear Part Quantity Main landing gear wires 2 Nose gear wire 1 Nose gear control horn 1 Landing gear straps 2 Wheels 3 Wheel collars w set screws 5 3mm x 10mm wood screws 4 Wing Assembly Part Quantity Right wing 1 Left ...

Page 3: ...d one small 2 Aluminum fuel tubing one short and two long 3 3mm x 18mm self tapping screw 1 Silicone fuel line 1 Tank collar 1 3 8 40 35 51 16 14 18 17 13 15 50 43 44 45 33 Parts shown smaller than actual size out of proportion 19 45 43 35 32 11 51 15 25 26 50 24 47 23 29 10 9 1 6 136 12 2 6 6 6 9 13 14 18 16 33 17 28 3 52 29 47 10 6 5 6 6 6 4 6 6 6 35 43 44 45 50 3 8 20 17 18 33 40 12 13 14 15 51...

Page 4: ...el engine The O S 40 FP SuperTigre GS 40 and Irvine 40 RC are just a few examples Look for features such as easy break in easy starting efficient carburetion and low maintenance Check the manufacturer s recommendations for propellers to use with your engine Radio Equipment To let you send the commands that control your SuperStar 40 s flight path you ll need a 4 channel aircraft radio system with f...

Page 5: ...irplane and radio 2 Disconnect the receiver battery switch harness and make sure that the transmitter is turned off Disconnect all batteries and drain all fuel 3 Include a list of all items returned and a THOROUGH written explanation of the problem and service needed If you expect the repair to be covered under warranty also include your proof of purchase 4 Include your full return address and a p...

Page 6: ...y an even coat of epoxy on both sides of the 2 wing joiner With the 3 wing joiner laying flat on the work surface stack 2 on top of 3 and 1 on the top of 2 Note The epoxy should be in between the layers of the plywood wing joiners and not on the outside surfaces Clamping the wing joiner 4 After epoxy has been applied to the 2 wing joiner and the joiners have been laminated use three 6 Assembling t...

Page 7: ...ven surface joints from the joiner edges and sides Caution A snug fit is desirable between the joiner and the wing cavity Do not sand excessively Viewing the wing dihedral 8 Pay close attention to the orientation of the wing joiner in relation to the dihedral of the wings as shown Gluing the joiner in the wing 9 Mix 1 4oz 7 5ml of 30 minute epoxy to glue the joiner into one wing half Use a mixing ...

Page 8: ... It may be necessary to prop one wing half up the tip of the wing would be 5 from the work surface with the other wing half flat on the work surface to hold the wing halves in alignment while the epoxy is curing Cutting the aileron servo hole 14 Remove the masking tape from the wing joint seam With the wing laying upside down and the leading edge facing away from you tape the aileron servo hole te...

Page 9: ... be placed against the wing when the servo tray is installed Assembling the servo tray 17 Apply thick CA to the flat side of the balsa servo tray mounting block Place the mounting block on the aileron servo tray next to the servo opening not on the outer edge of the tray Note the positioning of the dihedral angle in relation to the servo tray Test fitting the aileron servo 18 Test fit the aileron ...

Page 10: ...nd polyester It is specially made for the purpose of hinging model airplane control surfaces Properly installed this type of hinge provides the best combination of strength durability and ease of installation The CA hinges in your plane are preglued and must not be removed Check each of the ailerons the rudder and the elevator to be sure that they are secure Gently tug on each of the control surfa...

Page 11: ...e pushrods 24 Attach the aileron control rods to the aileron torque rods using the plastic clevises Pry the fork of the clevis apart and insert the pin of the clevis through the hole in the aileron control horn Press the forks of the clevis back together until they snap into place Aileron pushrods installed 25 Locate the 1 4 6 5mm diameter clear plastic tubing and cut two 1 4 6 5mm long pieces Do ...

Page 12: ...ation the servos should float freely on the rubber grommets What you ll need Parts in this kit Plus these general items Scrap plywood Paper towels 2 Foam wheels 6 minute epoxy 4 4mm Wheel collars 30 minute epoxy 4 2 x 5mm screws Silicone sealant Fuselage Ruler Pushrod guide tube Mixing sticks Steering pushrod Mixing cups Hardwood wing dowels Rubbing alcohol Plywood stabilizer mount Epoxy brushes H...

Page 13: ...poxy to lightly seal the dowels that are protruding from the outside of the fuselage This will keep fuel from soaking into the wooden dowels With the remainder of the epoxy secure the dowels in place by applying epoxy on the dowel from the inside of the fuselage next to the fuselage wall Wing dowels installed 6 The front wing dowel should measure approximately 5 8 15 5 mm on each side of the fusel...

Page 14: ...ocated at the rear of the fuselage behind the horizontal stabilizer slot are two balsa tail posts These posts are left for building alignment and fuselage construction guides Both of these posts must be removed in order to insert the horizontal stabilizer Using a sharp hobby knife cut the posts even with the slot as shown in the picture Vertical stabilizer slot covering 11 Using your finger locate...

Page 15: ... method will adjust the horizontal stabilizer to a 90Þ angle to the centerline of the aircraft Installing the stabilizer 16 Mix 1 4oz 7 5ml of 30 minute epoxy to install the horizontal stabilizer Using a mixing stick place glue inside the horizontal stabilizer slot on all sides including the horizontal stabilizer mount Insert the horizontal stabilizer and clean off the excess epoxy that squeezes o...

Page 16: ...e may be required to hold the fin during this time The stabilizers installed Check the elevator 20 The CA hinges in your plane are preglued and must not be removed Check the elevator hinges to be sure that they are secure Gently tug on the control surface at each hinge location If any of them seem loose reglue them as described on page 10 Check the rudder 21 Check the rudder hinges to be sure that...

Page 17: ...les with a felt tip pen Drill two 1 16 1 6mm holes through the elevator With two machine screws 2mm x 20mm attach the control horn Locating the rudder exit hole 26 The precut rudder pushrod exit hole is located on the same side as the rudder control horn under the covering 2 50 5mm in front of the rudder on the top of the fuselage Locate the exit hole by gently running your finger down the top of ...

Page 18: ...place them over the landing gear struts Using a felt tip pen mark the location of the strap mounting holes onto the bottom of the fuselage Drilling the fuselage 31 Drill the four holes using a 1 16 1 6 mm drill bit Mounting the struts 32 Using four 3 x 15mm self tapping screws fasten the landing gear straps to the bottom of the fuselage over the struts The struts should be flush with the bottom of...

Page 19: ...lar into the motor mount Leave a 7 16 11mm space between the control horn and mounting bracket Lock the collar by tightening the phillips head screw on the side of the collar Steering pushrod exit hole 36 Using a felt tip pen place a mark 5 16 8mm from the engine compartment and 1 25 5mm from the side of the fuselage on the bottom of the fuselage Drilling the exit hole 37 Using a 1 8 3 2mm bit dri...

Page 20: ...l tank assembly 41 Locate the three aluminum tubes that are used in the fuel tank The longest one will be used as the pressure line Bending the pressure line 42 Being careful not to kink the tube bend one end of the tube to a 90 angle It may be helpful to find a rigid object that can be used as a form to bend the tube around Leave 1 1 2 38mm of straight tube at one end so it can easily be inserted...

Page 21: ...w Do not overtighten the plastic stopper plates or damage to the tank may occur Installing the foam collar 45 Locate the 1 4 x 7 8 6 x 22mm foam tank collar Remove the inner foam circle and place the collar around the neck of the fuel tank Installing the tank 46 Insert the fuel tank into the fuselage as shown in the picture Make sure the foam collar is seated well against the firewall Orientation ...

Page 22: ...the proper locations on the engine fuel pick up to the carburetor pressure line to the muffler and fill line on the same side as the fuel pick up line The fill line should be plugged with a 3mm screw not included Installing the pushrod connector 4 Remove the wire control rod from the plastic guide tube Slide a pushrod connector on one end of the rod leaving 1 4 6mm extending past the connector Tig...

Page 23: ...n the picture Note It might be necessary to enlarge the hole in the spinner backplate for a proper fit over the engine shaft Place the washer and nut back onto the shaft The propeller must be seated in the spinner backplate correctly Tighten the nut using a 10mm wrench Final spinner assembly 7 Place the spinner cone onto the backplate until they snap together They must be aligned correctly for for...

Page 24: ... the two screws supplied with the switch Assembling the servos 3 Remove the servo arms and wheels from the three servos Install the rubber grommets that came with the radio system onto the servos following the manufacturer s instructions Servo installation 4 Install the three servos from your radio system as shown in the picture Refer to the radio manufacturer s manual for more detailed instructio...

Page 25: ... 1 6mm exit hole in the center of the rear window 1 25 5mm down from the edge of the radio compartment Route the antenna under the plywood servo tray and up through the exit hole Tie a knot in the antenna before it is fed through the exit hole to keep it from being pulled out of the receiver D Do o n no ot t cut the antenna wire The receiver is tuned to a specific length of antenna Securing the an...

Page 26: ...ening in the top of the carburetor Leave the throttle open about 1 16 1 5mm and secure the throttle pushrod in the pushrod connector Then cut off the excess pushrod 1 4 6 3mm past the pushrod connector Full throttle control movement Idle throttle control movement The throttle servo horn should move 40Þto the rear For idle speed move the throttle stick back with the throttle trim forward The carbur...

Page 27: ... move the pushrod connector closer to the center of the servo horn Increase throttle movement 12 To increase the movement of the throttle control rod move the pushrod connector on the throttle arm closer to the mounting screw The carburetor should be completely closed The throttle servo horn should be 45Þ to the rear To stop the engine move the throttle stick back and the throttle trim back The ca...

Page 28: ...de of the clevis Connect the clevis to the elevator control horn using the outer hole Connecting to the servo 17 Cut one arm from the servo horn to reduce the chance of interference with other control servos Lay the control rod on the second hole 1 2 12 5mm from the center of the servo Mark the control rod at the hole location Bend the rod down 90Þ and cut the control rod 1 4 6mm after the bend Th...

Page 29: ...l move up as shown on the control surface gauge The servo horn should move towards the rear To gain altitude or make the plane rise move the elevator stick back The elevator should be in the neutral position The elevator servo horn should be 90Þ to the servo Cut out the control surface gauge and glue it to a piece of scrap cardboard For level flight center the elevator stick 29 90 Front Rear ...

Page 30: ...rod on the rudder pushrod Connecting the servo 21 Using the same technique as described in Step 17 except use the whole servo horn connect the rudder control rod Note Make sure the steering gear is straight before marking the control wire Position the steering control rod over the rudder servo horn on the opposite side of the rudder linkage and mark the rod above the inside hole 3 8 from the cente...

Page 31: ...eel should turn left The rudder servo horn should rotate counter clockwise To turn the plane left move the rudder stick to the left The rudder should be at neutral The nose wheel should be straight ahead The servo horn should be 90Þ to the servo With the rudder stick centered the plane will fly straight 31 90 ...

Page 32: ...to move up farther than they do down This is called Aileron Differential and will help the airplane turn Position the control rods over the middle hole in the servo arm and mark the wire with a felt tip marker Cut the wire leaving 1 4 past the mark Connect the rods with retaining clevises as described in previous steps Attach the wing saddle tape 24 Apply a piece of wing saddle tape to each side o...

Page 33: ...left aileron will move up as shown on the surface control gauge The right aileron will move down The aileron servo horn should rotate clockwise To roll the plane to the left move the aileron stick to the left The ailerons should be at neutral The aileron servo horn arms should be equal on both sides For straight and level flight the aileron stick should be centered 33 ...

Page 34: ... construction should be complete the on board radio system should be installed and the wing attached The model is balanced by supporting it at two points on the underside of the wing one on each side of the fuselage approximately 3 3 4 back from the leading edge of the wing A pair of soft pencil erasers make good points to support the model and will not mark the bottom of the wing or let it slip l...

Page 35: ...tend to track better and be less sensitive to control inputs but will generally drop its nose when the throttle is reduced to idle This makes the plane more difficult to land since it takes more effort to hold the nose up A nose heavy airplane will have to come in faster to land safely Chamfer To slightly round off or bevel a corner Charge Jack The plug receptacle of the switch harness into which ...

Page 36: ... on board battery pack or transmitter battery pack Field Charger A fast battery charger designed to work from a 12 volt power source such as a car battery Flaps Hinged control surface located at the trailing edge of the wing inboard of the ailerons The flaps are lowered to produce more aerodynamic lift from the wing allowing a slower takeoff and landing speed Flaps are often found on scale models ...

Page 37: ...C Clubs require the use of mufflers Muffler Baffle A restrictor plate inside the muffler which reduces engine noise This plate can be removed to increase power but only if there are no noise restrictions where you fly Needle Valve Adjustment on a carburetor used to set proper fuel air mixture Some carburetors have separate needle adjustments for low and high throttle Typically turning the needle a...

Page 38: ...ny of the specialty airplanes and are best for general flying as they are the most versatile and durable Stall What happens when the angle of attack is too great for the wing to generate lift regardless of airspeed When the wing cannot generate lift the model falls out of the sky until sufficient airspeed is gained Then you can get control of the model this takes altitude and should be avoided upo...

Page 39: ...numbers must fly faster to stay in the air These are generally performance airplanes Conversely planes with lower numbers do not need as much air flowing around the wing to keep it flying Gliders and trainer airplanes fall into this category because slow efficient flight is desirable Wing Root The centerline of the wing where the left and right wing panels are joined Yaw Axis The airplane axis con...

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