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SIG FOUR-STAR 40 ARF, Assembly Manual, Page: 8 / 16

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SIG FOUR-STAR 40 ARF Assembly Manual Download Page 8

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MOTOR AND FUEL TANK INSTALLATION

 

Fuel Tank Assembly

 
The 260cc (8.7oz.) fuel tank supplied 
with this kit is now assembled. We 
suggest using a simple two line fuel 
system in this airplane. One fuel line is 
connected to the "clunk" or fuel pick-up 
line and the motor's carburetor. This 
same line will also be used to fill the 
tank. The second line is the overflow 
line for use when filling the tank. 

 
After filling the tank, this same line is then connected to the motor's muffler pressure nipple, providing muffler pressure to 
the tank. Note that the rubber stopper for the tank has two holes all the way through it. Use these holes for the two fuel 
lines. Gently bend the aluminum overflow tube upwards to 90O, to reach the top of the tank. Adjust the length of the 
internal silicon fuel tubing to allow free movement of the fuel pick-up inside the tank. Press the stopper assembly into the 
neck of the tank and secure by tightening the compression screw firmly. Do not over tighten this screw.

 

Motor Installation

 
Note: These instructions describe the installation of a typical 2-cycle motor. There are some variations between brands of 
motors so you may find some small details that are different for your installation. The same thing holds true if you are using 
a 4-cycle motor. Just adjust the mounting and throttle pushrod location to fit your installation.
 

This instruction sequence will install both the fuel tank 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  

4 6-32 Lock Nuts - not included 

 
1.

 
Feed the throttle pushrod housing into position in the holes in the firewall and the 
internal fuselage formers. Leave about 1" extending forward of the firewall. Use 
epoxy to secure the housing in place. The fuel tank is installed first. Apply a bead 
of silicon sealer around the neck of the fuel tank and install it into the fuel 
compartment, aligning the neck with the round hole in the firewall. Press the neck 
into the firewall hole. Allow the silicon sealant to cure before applying any 
pressure to the fuel lines.

 

 

 
2.

 
Glue the 8mm x 20mm x 76mm Balsa Fuel Tank Retainer into position against 
the front of the former at the rear of the fuel tank. Do not allow the retainer to 
block the throttle pushrod holes that are located in the former.

 
NOTE: The motor compartment was fuel proofed during production of the 
airplane. However, for a little extra insurance, you could give the motor 
compartment an additional coat of surfacing resin. If you decide to do this, use a 
brush to apply the resin and be sure to brush the resin up to the covering edges. 
In addition, YOU WILL HAVE TO SEAL THE EDGES OF THE FUSELAGE 
SIDES AFTER THEY ARE TRIMMED FOR MUFFLER AND NEEDLE VALVE 
CLEARANCE.

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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