Hobby-Lobby Telemaster 40 Deluxe Assembly Manual Download

Page: 25 / 30

Part #

Qty. Sheet #

SIZE

Material

Description

ACP

1/16” X 2-2/2” X 4”

AC PLY

Anti crush plate

3/32” X 4” X 48

AC PLY

Aileron horn

BCS

1/16” X 6” X 36”

BALSA

Bottom center sheeting, wing

BLE

1/16” X 4” X 36”

BALSA

Bottom leading edge sheeting, wing

BLE

1/16” X 4” X 36”

BALSA

Bottom leading edge sheeting, wing

BS-A

1/8” X 4” X 36”

BALSA

Bottom sheeting part A, fuselage

BS-B

1/8” X 4” X 36”

BALSA

Bottom sheeting part B, fuselage

CS-A

1/16” X 4” X 36”

BALSA

Center section sheeting part A, wing platform

CS-B

1/16” X 4” X 36”

BALSA

Center section sheeting part B, wing platform

CS-C

1/16” X 4” X 36”

BALSA

Center section sheeting part C, wing platform

CS-D

1/16” X 4” X 36”

BALSA

Center section sheeting part D, wing platform

3/32” X 4” X 48

AC PLY

Elevator horn

EJ-A

1/4” X 4” X 7”

BASSWOOD Elevatot joiner part A

EJ-B

1/8” X 4” X 36”

BALSA

Elevatot joiner part B

1/8” X 12” X 12”

AC PLY

Fuselafe former #2

1/8” X 12” X 48”

LPLY

Fuselafe former #3

1/8” X 6” X 17”

LPLY

Fuselafe former #4

1/8” X 12” X 48”

LPLY

Fuselafe former #5

1/8” X 12” X 48”

LPLY

Fuselafe former #6

1/8” X 12” X 48”

LPLY

Fuselafe former #7

1/8” X 12” X 48”

LPLY

Fuselafe former #8

1/8” X 12” X 48”

LPLY

Fuselafe former #9

1/4” X 4” X 36”

BALSA

Fuselage side part A

FAM-B

1/8” X 12” X 48”

LPLY

Float aft mount part A

1/8” X 12” X 48”

LPLY

Float aft mount part B

1/32” X 12” X 30” AC PLY

Fuselage doubler

1/8” X 12” X 48”

LPLY

Fuselage floor

3/32” X 4” X 48

AC PLY

Flap horn

FHA

1/8” X 6” X 17”

LPLY

Fuselage hatch part A

FHA-H

1/8” X 12” X 12”

AC PLY

Fuselage hatch part H

FJ-A

1/4” X 4” X 7”

BASSWOOD Hatch magnet retainer

FLE

1/8” X 3” X 36”

BALSA

False leading edge, wing

FLHP-A

1/8” X 12” X 48”

LPLY

Float hard point part A

FLHP-B

1/8” X 12” X 48”

LPLY

Float hard point part B

FS-A

1/8” X 12” X 48”

LPLY

Fuselage side part A

FSB

1/8” X 12” X 48”

LPLY

Fuselage side part B

FST

1/4” X 5” X 12”

LPLY

Fuselage servo tray

FTD

1/8” X 12” X 48”

LPLY

Fuselage turtle deck

FTGM

1/4” X 5” X 12”

LPLY

Fuselage tail gear mount

FW-A

1/8” X 12” X 48”

LPLY

Firewall part A

FW-B

1/8” X 12” X 48”

LPLY

Firewall part B

FWBP

1/4” X 5” X 12”

LPLY

Fuselage wing bolt plate

FWS

3/16” X 4” X 36”

BALSA

Fuselage wing saddle

Summary of Contents for Telemaster 40 Deluxe

Page 1: ...Telemaster 40 Deluxe MADE IN THE USA Assembly Manual Hobby Lobby International 5614 Franklin Pike Circle Brentwood TN 37027 USA Phone 866 512 1444 ...

Page 2: ......

Page 3: ... 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 fit 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 primar...

Page 4: ...n a piece of scrap wood to prevent the fiber 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 finish in stalling the nail When done the nail head should be in the recess so the block can sit flat on the bench Repeat this process with the second pinning...

Page 5: ...ssembly 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 4 The fuselage sides are supplied in two sections FS A and FS B they are joined by a finger 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 ...

Page 6: ...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 instal...

Page 7: ...ed 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 floats you will need to install the float hard point Remove the dash cut material just behind F4 includ ing a notch in the square stringer Assemble F2 from two 1 8 ply sections us...

Page 8: ...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 ABOV...

Page 9: ...nd 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 float 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 a...

Page 10: ...ovided 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 con...

Page 11: ... 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 fl...

Page 12: ... 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 flat washers c 33 This concludes the basic...

Page 13: ...he plans and pin in place with push pins c 4 Install and glue the false trailing edge SFTE to the aft edge of SP The center notch will position it correctly c 5 install and glue two S1 ribs in the notches provided c 6 install but do not glue two stabilizer sheer webs SSW These will remain loose un til all the ribs have been installed c 7 install but do not glue all remaining stabi lizer ribs S2 th...

Page 14: ...ge and the false leading flush 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 fin Install the top spar from 1 8 X 1 2 basswood stock Taper the ends to butt fit to the stabilizer tips SWT When your satisfied with the fit of t...

Page 15: ...e 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 1 Prepare all rudder components R1 R2 R3 A and two R3 B Glue R2 to R1 note the correct orienta...

Page 16: ...n where the dorsal fin VF intersects with it Extend the hing slots into V4 This completes the vertical fin assembly Wing joiner platform assembly Locate and prepare the wing platform WP Note that the wing platform is not built over the plans c 2 Use the registration pin system to install WP F at the aft end of WP c 3 The wing joiner WJ must be laminated from two 3 32 ply parts Use the regis ter pi...

Page 17: ...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 PlaceCS Aonapieceofparchment 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...

Page 18: ...nk 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 1 Loc...

Page 19: ...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 flip the assembly over Glue SBC to SW T at the inboard en...

Page 20: ...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 ...

Page 21: ... move any glue that squeezes out into this area as it will interfere with the center sheeting when it is installed later c 19 Locate the cardboard cable tunnel tube and cut one piece 6 3 8 long and another 9 3 8 long Install the 9 3 8 section first into the holes in the wing ribs Push this tube through until it just protrudes through W7 Install the 6 3 8 tube until it just pro trudes through W3 Gl...

Page 22: ...par flange SPF B in the same manner as you did the top spar flange c 26 From the bottom of the wing assembly glue the leading edge sheeting to each rib and the leading edge This is easily done by applying finger pressure to the sheet ing at each rib and applying thin CA Start at the center of the wing and work out in one direction to the end Then return to the center and complete the process in th...

Page 23: ...teristics This concludes the assembly of the left wing panel Return to step one of the wing assembly instructions and repeat steps 1 through 35 for the right wing panel Remember to reverse the pro cedure to install SBC onto the sheer webs Sand all surfaces in preparation for covering Cover the wings with your preferred covering system Use Epoxy or PU glue to assemble the wing platform and the wing...

Page 24: ...nd down to them and then glue on the top sheeting FLT The flap control horn can be installed af ter the flap has been covered When installing the flap onto the wing it is a good idea to pin the hinges after gluing This can easily be accomplished bu drill ing a 1 16th inch hole through the bottom sheeting the hinge and the flap leading edge and wing trailing edge and the glu ing in a round tooth pi...

Page 25: ...LPLY Fuselafe former 5 F6 1 19 1 8 X 12 X 48 LPLY Fuselafe former 6 F7 1 20 1 8 X 12 X 48 LPLY Fuselafe former 7 F8 1 19 1 8 X 12 X 48 LPLY Fuselafe former 8 F9 1 20 1 8 X 12 X 48 LPLY Fuselafe former 9 FA 2 11 1 4 X 4 X 36 BALSA Fuselage side part A FAM B 1 20 1 8 X 12 X 48 LPLY Float aft mount part A FB 1 19 1 8 X 12 X 48 LPLY Float aft mount part B FD 2 10 1 32 X 12 X 30 AC PLY Fuselage doubler...

Page 26: ... X 36 BALSA Rudder part 1 R2 1 12 1 4 X 4 X 36 BALSA Rudder part 2 R2 B 2 1 1 16 X 2 2 2 X 4 AC PLY Rudder hard point part B R3 A 1 20 1 8 X 12 X 48 LPLY Rudder hard point part A RU 1 24 3 32 X 4 X 48 AC PLY Rudder S1 2 12 1 4 X 4 X 36 BALSA Stabilizer rib 1 S2 2 26 3 32 X 3 X 36 BALSA Stabilizer rib 2 S3 2 26 3 32 X 3 X 36 BALSA Stabilizer rib 3 S4 2 26 3 32 X 3 X 36 BALSA Stabilizer rib 4 S5 2 2...

Page 27: ...28 3 32 X 3 X 36 BALSA Rib 1 wing W10 1 29 3 32 X 3 X 36 BALSA Rib 10 wing W10 1 30 3 32 X 3 X 36 BALSA Rib 10 wing W11 1 29 3 32 X 3 X 36 BALSA Rib 11 wing W11 1 30 3 32 X 3 X 36 BALSA Rib 11 wing W12 1 29 3 32 X 3 X 36 BALSA Rib 12 wing W12 1 30 3 32 X 3 X 36 BALSA Rib 12 wing W2 2 27 3 32 X 3 X 36 BALSA Rib 2 wing W2 2 28 3 32 X 3 X 36 BALSA Rib 2 wing W3 2 27 3 32 X 3 X 36 BALSA Rib 3 wing W3 ...

Page 28: ...3 32 X 3 X 36 BALSA Wing platform dowl support WP F 1 11 1 4 X 4 X 36 BALSA Wing platform filler WP FLE 1 18 1 8 X 3 X 36 BALSA Wing platform false leading edge WP LE 1 11 1 4 X 4 X 36 BALSA Wing platform leading edge WS 1 23 3 16 X 4 X 36 BALSA Windshield fuselage WSG 4 22 1 8 X 4 X 36 BALSA Wing sheeting gusset WSM 4 19 1 8 X 12 X 48 LPLY Wing servo mount WSMB 8 16 1 8 X 12 X 12 AC PLY Wing serv...

Page 29: ...27 ...

Page 30: ...Hobby Lobby International 5614 Franklin Pike Circle Brentwood TN 37027 USA Phone 866 512 1444 ...

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