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SIG 4-STAR 60 Building And Flying Instructions Download Page 23

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58.

a. Repeat steps 53 and 54 to attach the rudder to the fin. Use four hinges in the rudder.  
b. After the glue has cured (about an hour) flex all the hinge lines in each direction a couple dozen times to reduce any 

stiffness. 

 
59.

 
Swivel the nylon tailwheel bracket into position on the bottom of the fuselage, and mark the two mounting holes. Drill at the 
marks with a 5/64" drill and screw the bracket to the fuselage with two #4 x 1/2" sheet metal screws.

 
60.

 
Install the two 3-1/4" main wheels on the aluminum landing gear using the hardware as shown on plan sheet #1. Once the 
wheels have been attached, the landing gear assembly can be bolted to the fuselage using the three 6-32 x 1/2" mounting 
bolts.

 
61.

 

a. If you wish to install a pilot, now is the time to do it. A William's Brothers 

2-5/8" Sportsman pilot was used in our prototype models. Be sure to glue 
it firmly so it won't come loose in flight.  

b. Cut the excess plastic from the canopy using scissors. Cut to the molded 

line on the sides, and around the front. Cut across on the sharp corner 
across the back. Sand the rough edges smooth, being careful not scratch 
the clear plastic.  

c. Trial fit the canopy to the fuselage and trim it as necessary for a good fit. 

Position the canopy fore and aft so that the raised frame ends at the rear 
tips of the front top deck and tape it down.  

d. With a soft pencil, draw a line forward on the fuselage along the bottom 

edge of the canopy, over the front top deck and back along the side. Remove the canopy and carefully cut away a 
1/16" wide strip of covering using the line as your guide. The idea is to expose a strip of bare wood where the 
canopy makes contact so that it can be securely glued to the fuselage.  

e. Check the fit and location of the canopy one more time. If everything is correct wash the canopy with soap and 

water and dry thoroughly. Now is the time to apply trim tape to the inside of the canopy on the raised area to 
simulate a frame. Tape the canopy to the fuselage and apply glue along the bottom edge of the canopy.  

f. Dress up the bottom edge of the canopy by applying 1/4" striping tape, half on the canopy and half on the fuselage. 

Start at the rear corner of one side and work forward up and over the front deck and back along the other side. 
Another piece of striping tape will finish off the rear edge of the canopy. 

 

BUILDER'S TIP: 
CA can be used without fear of fogging the canopy if a light spray of accelerator is applied before taping the canopy 
down. Use MEDIUM CA as it will not wick as far nor as quickly as THIN CA.

 

Engine And Fuel Tank Installation

 
62.

 

a. Engine installation in the FOUR-STAR 60 is simply a matter of bolting the 

engine and engine mount in place on F-1.  

b. Install the throttle cable on the carburetor arm and assemble the pushrod 

connector on the throttle servo arm. The exact position of the cable in the 
pushrod connector will have to be adjusted after the rest of the radio has 
been installed.  

c. If the construction of the fuselage followed these instructions, installation 

of the tank is just a matter of sliding the tank through the wing opening 
and blocking in place. Like most SIG kits, the fuel tank in this model is 
installed from the rear of the fuel tank compartment rather than through a 
removable hatch. This choice was made for several reasons: hatch 
openings make the nose weaker, it's very difficult to keep oil from leaking in around a hatch, a method of fastening 
the hatch must be built into the fuselage, adding to the complexity and construction time of the model. Further, fuel 
tanks that are installed properly seldom need to be removed for maintenance. 

 

Radio Installation

 
63.

 

a. Mount the elevator, rudder and throttle servos in the laser cut plywood tray provided with the kit.  
b. Place the tray in the slot in the doubler. The fore and aft location of the servos will vary depending on engine weight, 

so it will be necessary to do a preliminary balance with the model to establish the tray position. Reinforce the servo 
traylfuselage joint with leftover 1/8"x5/16" balsa stringer scraps.  

c. Cut off the front ends of the outer pushrod tubes about an inch behind the rear of the servo tray. 

Summary of Contents for 4-STAR 60

Page 1: ...lly assembled A model airplane that is not built properly will not fly properly Remember to work slowly and follow the instructions exactly SIG as the kit manufacturer can provide you with a proven aerodynamic design quality materials and detailed instructions but ultimately the flyability of your finished model depends on how well YOU put it all together ...

Page 2: ... Braces D 2 1 3 8 x4 x36 SHT 11 Elevators and Rudder 1 1 4 x4 x36 SHT 12 Stabilizer and Fin Balsa Sheet 4 3 32 x2 x36 Wing Trailing Edge Sheet 4 1 16 x3 x36 Stabilizer and Fin Sheet 2 3 32 x4 x36 Wing Center Sheet Balsa Sticks 8 3 16 x3 16 x36 Forward Spars 6 1 4 x1 2 x36 Main Spars and Doublers 5 1 8 x5 16 x24 Rear Fuselage Stringers 4 1 4 x1 4 x36 Rear Wing Spars 1 3 4 Triangle x18 Firewall Wing...

Page 3: ...Rudder Elev 2 270 o d x36 Nylon Outer Pushrod Tubing Rudder Elev 1 130 o d x18 Nylon Tubing Throttle Pushrod 1 1 16 Dia x18 Steel Cable Throttle Push rod 1 2 x30 Fiberglass Tape Wing Center Joint and Tailwheel Wire and Elevator Joiner Wire 22 Easy Hinges 1 38 x50 Plate 1 Full Size Plan 1 38 x50 Plate 2 Full Size Plan 1 28 Page Photo Illustrated Instruction Book 2 5 x17 1 2 Paper Aileron Servo Lead...

Page 4: ...ate each aileron elevator rudder and engine throttle of your 4 STAR 60 The 4 STAR 60 s fuselage is spacious enough that any common brand of radio equipment with standard size servos and battery pack can be used Be certain that your radio system transmits on one of the FCC approved frequencies for R C model aircraft 1 2 x 8 x 12 Soft Foam Rubber such as SIGRF240 Use this foam rubber to protect your...

Page 5: ...board you ll see us using in the photos in this book is an 18 x50 piece of 3 4 thick plywood perfectly flat with a same sized piece of 1 4 thick foam board stuck down on top of the plywood with double sided sticky tape The plywood provides the rigidity and flatness we need and the semi flexible foam board lays flat on the plywood and gives us a surface to push pins into All materials were obtained...

Page 6: ...oint A good rule of thumb If you don t see a slight fillet of glue around a joint it means the first application of glue has soaked completely into the wood and you should apply a second coat of CA Like any other adhesive we don t want to end up with gobs of CA glue on the outside of the joints Apply just enough glue to wet the joint area and leave a small reinforcing fillet around the joint That ...

Page 7: ...the joint with epoxy or water based glue or vice versa The different bonding mechanisms of these unrelated adhesive families will interfere with each other and a poor heavy joint is the result Use only one type of glue in each joint FOR ULTRA QUICK ASSEMBLY of two large pieces where positioning is easy try putting MEDIUM or THICK CA on one of the parts then spray ACCELERATOR directly onto the othe...

Page 8: ... R C model airplanes While AMA membership is not mandatory it is a good idea and we encourage all new R C fliers to join the AMA Membership in the AMA provides you with important liability insurance protection in case your R C model should ever cause serious property damage or personal injury to someone else For more information contact ACADEMY OF MODEL AERONAUTICS 5161 East Memorial Drive Muncie ...

Page 9: ... top of the trailing edge flush with the rear edge of the ribs c Cut and sand the dihedral angle on one end of the pre shaped 1 2 x1 trailing edge fill in blocks When the angle and length are correct glue the block in place between the two W l wing ribs on the trailing edge sheet 6 Trim one edge of a 3 32 x2 x36 balsa trailing edge sheet straight For this step it is recommended that you apply SIG ...

Page 10: ...ther is raised The bottom of the raised wingtip should be about 1 7 8 above the surface of the table A variation of up to 1 2 either way is acceptable and will not affect flight performance Most important is to have a tight joint at the wing center with no gaps b Use epoxy either SIG 5 MINUTE or SLOW CURE to join the two wing panels Apply glue generously to the end ribs and the dihedral brace Work...

Page 11: ... flush and square with the wingtip Aileron Servo Installation 17 a Cut four hatch rails from the special cut 1 4 x1 2 x16 basswood stick provided in the kit Glue the hatch rails flush with the bottom edge of the W 4 wing ribs in each wing panel The hatch rails provide a seat for the aileron hatch and a flat surface for attaching the covering material b Lay one laser cut 1 16 plywood hatch on the r...

Page 12: ...ight and one left are used on the left and right ailerons respectively NOTE The aileron servo must be centered electronically before continuing d Center the upright portion of the control horn on the aileron at the mark made in step b Vertically line up the clevis attachment holes with the point of the leading edge bevel Mark the position of the control horn mounting holes and drill a 5 64 hole at...

Page 13: ... them in place Be careful not to get any glue in the threads of the blind nuts 21 a Using the side view of the plans as a guide position the engine on the mounts so the propeller will clear the fuselage cheeks by 1 8 to a 1 4 and mark the engine mounting holes Keep the engine as far back on the motor mounts as possible b Remove the motor mounts from the firewall and drill the holes for the engine ...

Page 14: ...re with the fuselage top If necessary gently twist or push the parts in the desired direction and use masking tape to hold them there BUILDER S TIP To assist in keeping the nose section of the fuselage straight you can install the laser cut lite ply tank floor at this time but DO NOT GLUE IT IN PLACE b Glue all of the parts in place working trom the inside of the fuselage first using MEDIUM CA Sta...

Page 15: ...e pushrod and check for any binding Correct any problems now as it will be hard to get to this area later on 33 a Glue the balsa top deck formers T 1 T 2 and T 3 into the correct slots in FT Note that T 1 is placed in front of and slightly lower than the top of FT b Bevel the top edge of the fuselage sides with a sanding block to match the formers to provide a firm seat for the fuselage top deck N...

Page 16: ... Place the wing on the fuselage and check the fit If everything was properly built the wing should fit into the opening without any gaps If the wing does not fit properly now is the time to sand off any bumps or fill any hollows to match the contour of the wing DO NOT CHANGE THE INCIDENCE OF THE WING c Tape the wing to the fuselage and take measurements from the wing tip to the tail of the fuselag...

Page 17: ...sheets will be used for the fin skins b Separate the skins from the waxed paper and sand the joints smooth BEFORE attaching them to the stabilizer Sanding the skins after attaching them to the framework will result in a ripple effect 43 a Sand the top and bottom of the stabilizer frame to smooth out the glue joints Also sand the ends of the leading and trailing edges b Apply THICK CA or SIG BOND t...

Page 18: ... Temporarily pin or tape the stabilizer to the fuselage Trial fit the fin in the fuselage and on top of the stabilizer It may be necessary to trim the length of the fin trailing edge to allow the base of the fin to set on top of the stabilizer Leave the fin in place until after the tailwheel has been fitted b Round off the trailing edge and the bottom of the laser cut 3 8 balsa rudder Sand two 300...

Page 19: ...e during final assembly 51 a The balsa tail fairing blocks can now be glued to the fuselage using the stabilizer and the fin to position them accurately Cut two 3 lengths of 1 2 balsa triangle stock to serve as tail fairing blocks Make sure your fin is centered on the fuselage as viewed from above then carefully glue the fairing blocks to the back of F 6 not the tail surfaces Gently slide the fin ...

Page 20: ...rneath Laying a small strip of plastic or cardstock under the trim line makes it much easier to trim and eliminates the worry of cutting the covering underneath Wait until both the top and bottom pieces of covering material have been sealed completely around their edges before shrinking the large open areas between the ribs Alternate between the top and the bottom surface to avoid uneven shrinking...

Page 21: ...root of the wing and brush clear dope along the tight edge The dope will soak through the fabric adhere to the dope already on the framework and lock the fabric in place When the dope has set move to the wingtip and snug up the fabric spanwise and chordwise and brush clear dope through the fabric Repeat the tensioning doping sequence all around the rest of the wing Allow the dope to dry before tri...

Page 22: ...l response the gap should be as small as possible but big enough to allow full movement of the control surface without binding 2 EASY HINGES were designed to use THIN CA for maximum glue penetration Place three or four large drops of THIN CA directly onto the hinges in the gap The glue will wick into the slot as it penetrates both the wood and the hinge Continue this process gluing the same side o...

Page 23: ...ge and apply glue along the bottom edge of the canopy f Dress up the bottom edge of the canopy by applying 1 4 striping tape half on the canopy and half on the fuselage Start at the rear corner of one side and work forward up and over the front deck and back along the other side Another piece of striping tape will finish off the rear edge of the canopy BUILDER S TIP CA can be used without fear of ...

Page 24: ... the linkage SAFETY TIP Use a small length of fuel tubing over top of the RIC link This will keep the link from popping open during flight causing a loss of control A drop of THIN CA on both ends of each push rod where the wire enters the tubing will insure that the wires will not pull out of the plastic tubes 67 a Hook up the ailerons by installing control horns and aileron pushrods The servo lea...

Page 25: ...n aircraft to fly but it is not a basic trainer If you have little or no R C flying experience SIG strongly suggests that you get an experienced pilot to help you fly your model until you re comfortable with the controls Contact a local R C club or ask your hobby dealer for the names of good fliers in your area and a suitable location for flying Make any changes especially to the balance point gra...

Page 26: ... Copyright SIG Mfg Co Inc SIG MFG CO INC Montezuma Iowa 50171 0520 ...

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