SIG FOUR-STAR 40 ARF Assembly Manual Download Page 5

2.

Use Sig Slow Cure epoxy to join the two wing panels together. Apply the glue 
generously to the end ribs, Work some glue into the joiner slots and coat the 
hardwood joiner. Carefully slide the wing halves into place and hold them in the 
proper alignment with tape until the epoxy cures. Wipe away any excess epoxy 
that oozes from the center joint with a paper towel or a rag dampened with 
isopropyl alcohol before the glue cures. Be careful that the leading and trailing 
edges of the two wings are perfectly aligned and that there is no built in twist.

 

Installing The Aileron Servo And Pushrods

For the following steps you will need:

1 each Joined wing with ailerons installed 

1 each 3mm Plywood Aileron Servo Tray  

1 each Aileron Servo 

2 each 2mm x 200mm Pushrod 

2 each 2mm Nylon R/C Links  

2 each 2mm Solder R/C Links 

 
1.

 
Center the 3mm Plywood Aileron Servo 
Tray over the cutout in the top of the 
wing. The tray has a doubler glued to 
one end to make it thicker. This end is 
the front. When properly positioned, use 
a felt tip pen to mark the front and back 
edges.

 

 

 

 

 
2.

 
Remove the servo tray and carefully cut 
the covering away from the areas where 
the servo tray makes contact with the 
wing. Now use thin C/A to glue the 
servo tray into position.

 
3.

 
Test fit the aileron servo in the servo 
tray. The servo output arm should be 
facing the trailing edge of the wing. The 
servo tray may be trimmed slightly to 
allow the servo to fit. Also, the center 
wing ribs may interfere with the wire 
where it exits the servo. If this is the 
case you may trim away the ribs as 
needed.
Note: We recommend using servo output arms for the aileron servos. The arms should be at 90 deg. to the servo when the 
aileron control stick on the transmitter is in neutral an the transmitter trims are in neutral as well.

 
4.

 
Fit the servo into the servo mount in the 
wing panel. Take up any slack in the 
servo cable as you insert the servo by 
pulling on the end of the cable where it 
exits the top of the of the wing. Use a 
pin vise and a small drill bit to drill small 
pilot holes in the servo mount for the 
servo mounting screws. Use the screws 
supplied with your radio system to 
mount the servo securely in place on 
the servo tray.

 

 

 
5.

 
Thread one of the 2mm Nylon R/C Links onto the 2mm x 200mm Pushrod so that 
the barrel of the connector is centered on the threaded section of the pushrod.

 
6.

 
Attach the Nylon R/C Links and pushrod to the second to last hole in the aileron 
servo output arm. Place a 2mm Solder R/C Link into the hole in the fitting on the 
aileron torque rods.. Hold the aileron pushrod against the solder link. Make sure 
that the servo is still in the neutral position and tape the aileron into approximately 
neutral position. Mark the pushrod wire 1/8" beyond the end of the center barrel 
of the solder link.

Summary of Contents for FOUR-STAR 40 ARF

Page 1: ...FOUR STAR 40 flight envelope The FOUR STAR 40 ARF kit has been engineered to get you into the air quickly as possible with an R C model that will truly last The airframe has been expertly built and covered with AeroKote This material is both rugged and easy to repair The covering trim scheme is provided on two large peel stick mylar decal sheets This assembly manual has been specifically sequenced...

Page 2: ...al Your FOUR STAR 40 ARF has been professionally covered using AeroKote This material is well known for its ease of application light weight and consistency of color If you live in a dry climate you may notice that some wrinkles might develop after removing the covered parts from their plastic bags This is perfectly normal in low humidity climates Your model was built and covered in a part of the ...

Page 3: ...R C Links for elevator 1 rudder 1 throttle 1 ailerons 2 2 2mm x 200mm Pushrod for aileron 2 4 2mm x 20mm threaded stud for elevator 1 rudder 1 throttle 2 2 2mm x 100mm Pushrod for elevator 1 rudder 1 Miscellaneous 1 3mm Formed Aluminum Main Landing Gear 1 Molded Clear Plastic Canopy 1 2 pc Adjustable Motor Mounts 40 size 2 7 0cm dia approx 2 3 4 Main Wheels 1 25mm dia approx 1 Tailwheel 1 2 dia Sp...

Page 4: ...w of glue 4 Remove the pins from the next hinge and repeat the gluing process Finish gluing the rest of the hinges in the same manner Remove the tape that is holding the flexed aileron in position and flex the aileron in the opposite direction and re apply the masking tape to hold it in this position Now apply 4 5 drops of thin CA glue to the bottom of each hinge on the aileron Remove the masking ...

Page 5: ...The servo output arm should be facing the trailing edge of the wing The servo tray may be trimmed slightly to allow the servo to fit Also the center wing ribs may interfere with the wire where it exits the servo If this is the case you may trim away the ribs as needed Note We recommend using servo output arms for the aileron servos The arms should be at 90 deg to the servo when the aileron control...

Page 6: ... x 12 Iron on Covering Strip 1 Now mount the wing onto the fuselage and install the nylon bolts through the wing and into the blind nuts installed in the fuselage Now remove the wing and bolts form the fuselage 2 Take the 3 8 x 12 Iron on Covering Strip and apply it to the bottom of the wing to cover the joint at the center of the wing The strip should start at the bottom of the finger at the lead...

Page 7: ... Use a wrench to thread the locknut onto the axle Stop the locknut when it is close but not touching the hex nut A space between the nuts equal to about 3 or 4 sheets of copy paper is good Now hold the lock nut from turning with one wrench while using another wrench to tighten the hex nut tight against the lock nut There should be a slight amount of play and the wheel should rotate freely on the a...

Page 8: ...and the motor Therefore you will need the following The Motor with muffler removed not included The Assembled Fuel Tank 1 Throttle Pushrod Housing 1 8mm x 20mm x 76mm Balsa Fuel Tank Retainer 2 Motor Mounts 4 M3 x 20mm Phillips Head Screws 4 M3 Flat Washers 4 M3 Split Lock Washer 2 9 Lengths of Silicon Fuel Tubing not included 4 6 32 x 1 1 2 Socket Head Screws not included 4 6 Washers not included...

Page 9: ...e for clearance There should be about a 1 8 gap between the fuselage side and the bottom of the muffler needle valve After the fuselage sides have been trimmed for the proper clearance seal them with epoxy to fuel proof the bare wood Now reinstall the motor securely to the mount Use a little thread locking compound on all screws when assembling these components The muffler should be mounted after ...

Page 10: ...gs in the top view Lay the stab in place being careful to align it squarely and that the slot at the rear of the stab is aligned with the fuselage sides With the fuselage on a flat surface sight the model from the front The stab should be absolutely aligned with the wings without leaning to one side or the other If it is leaning use a small weight or a little masking tape to straighten it out 8 No...

Page 11: ...rommets and eyelets supplied with your radio system onto the rudder elevator and throttle servos Install all three servos in place into the fuselage servo tray again using the screws supplied with your system We have found it handy to label the servo leads for easy identification when plugging them into the receiver 2 The on off switch should be mounted on the fuselage side opposite of the motor e...

Page 12: ...he same manner as the rudder horn Note that the elevator horn is angled slightly inward toward the fuselage to line up with the pushrod exit Install both the rudder and elevator pushrods into their exits from the rear of the fuselage and snap the R C links in place to the nylon horns 6 The pushrod connections are now made for the rudder and elevator servos Begin by neutralizing the rudder and hold...

Page 13: ...p fit over the motor s prop shaft Slip the spinner back plate onto the prop shaft and onto the adapter ring The propeller is installed next followed by the nose cone The cone is held in place with the provided screws Be sure to snug the screws securely in place but do not over tighten them Install the muffler onto the motor and connect the fuel tank vent line to the pressure outlet on the muffler ...

Page 14: ...e such as two dowels with rubber tips to protect the finish It is the most accurate method for determining and adjusting the correct balance point However since the balance point is located at the main wing spar on this airplane you and a friend can lift the assembled model at the wing tips to check the balance The airplane should balance perfectly level If the nose hangs down the model is nose he...

Page 15: ...er the end of the runway In crosswind situations a little rudder input will likely be needed to keep the airplane lined up with the runway The FOUR STAR 40 is best landed in the three point position As long as we re on the subject no landing gear system is bulletproof Your FOUR STAR 40 ARF has a great landing gear system that has proven to be very tough on both grass and asphalt flying fields Howe...

Page 16: ... HOTLINE for technical support 1 641 623 0215 SIG WEB SITE www sigmfg com Copyright SIG Mfg Co Inc SIG MFG CO INC Montezuma Iowa 50171 0520 LIMIT OF LIABILITY The craftsmanship attention to detail and actions of the builder flyer of this model airplane kit will ultimately determine the airworthiness flight performance and safety of the finished model SIG MFG CO s obligation shall be to replace tho...

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