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SIG Four-Star 40 SIGRC44, Building And Flying Instructions, Page: 7 / 22

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SIG Four-Star 40 SIGRC44 Building And Flying Instructions Download Page 7

. 

 
4.

 
Install a pre-cut 3/32"x3"x1-3/16" balsa shear web in each rib bay except the one between the two most inboard W-1 ribs 
(where the dihedral brace will be installed later). Notice that the wood grain is vertical for maximum strength. Trial fit each 
web before gluing, sanding the ends as necessary to make them fit snugly between the ribs on either side. The bottom of 
the shear webs should be centered on the bottom main wing spar; the top of the shear webs should be centered on the 
notch for the top main wing spar. 
 
NOTE: The shear web to be installed between the second and third W-1 wing ribs will need to be shortened significantly to 
fit.

 
5.

 

a. Trial fit the 3/16"x3/8"x30" spruce top main wing spar. If any of the shear webs are too tall, they should be trimmed to 

allow the spar to sit all the way down in the rib notches. When satisfied with the fit, glue the spar in place. Check the 
inboard W-1 rib again with the Dual Tool to be sure it is still at the correct angle.  

b. Glue the 5/16"sq.x30" balsa leading edge to the front of the ribs.  

c. Glue the 3/16"sq.x30" balsa top forward spar in the rib notches. 

NOTE: Remove any pins from tbe structure that are located under the area where the top center sheeting will be installed 
(in the next step). Otherwise, you may find it difficulf to remove your wing from the board later!

 
6.

 
Pieces for the top center sheeting should be cut from the 1/16"x3"x30" balsa provided in the kit. Again, Sig-Bond is 
recommended for the front and rear edges of the sheeting to make it easier to sand the joints smooth. Also use Sig-Bond 
on the center W-1 rib. The sheeting can be glued to the ribs on each end using CA.
 

 

 

 
7.

 
When the glue has dried, unpin the wing half from the board and install the 3/16"sq.x30" balsa bottom forward spar. 
 

IMPORTANT: If you have been using thin or medium CA glue during construction, now is the time to go back 
over every joint using medium or thick CA. Don't be stingy here - the integrity of your wing depends upon 
strong glue joints. Glue each side of each joint. Make certain the shear webs are bonded to the spars AND 
the wing ribs on each side. Double check the L.E. stick and the T.E. sheeting for complete bonding to the 
ribs.

 
8.

 
Install the bottom center sheeting except in the area between the bottom forward spar and the bottom main wing spar. Cut 
pieces for the sheeting from the 1/16"x3" balsa that you used earlier.

 
9.

 
Cut oft and sand the spars, L.E., T.E., and sheeting at both ends of the wing flush with the end ribs.

 
10.

 
Sand the leading edge to a round crosssection as shown in the diagram below. 
NOTE: The L.E. notches in the ribs were intentionally made slightly oversize so the ribs could be sanded down to the 
leading edge.

Summary of Contents for Four-Star 40 SIGRC44

Page 1: ......

Page 2: ...on the fuselage instead of the wing simplifies wing construction and lowers the parts count The tailwheel is a bit unique in that it s attached directly to the rudder without the usual plastic tailwheel bearing We ve tested this installation quite extensively without any problems The amazing strength of EASY HINGES and cyanoacrylate adhesive make this simple effective tailwheel installation possib...

Page 3: ... in contact and positioned correctly before glue application This feature is useful when laminating large sheeted areas like a fuselage side and a fuselage doubler Sig Kwik Shot Accelerator Spraying accelerator on CA any thickness will cure it almost instantly Although CA is fast it s sometimes nice to speed it up even more Debonder This can be used to separate parts but you ll probably use it for...

Page 4: ...lable Plan ahead Read the book completely and study the full size plans before beginning construction Refer to The Basics of Radio Control In addition to the instruction booklet you are reading now the booklet The Basics of Radio Control has been included with this kit as a reference for installing the engine fuel tank and radio in the FOUR STAR 40 It also contains very important information on pr...

Page 5: ...ottle pushrod 4 2 56x10 Threaded Rods 2 ailerons l elevator l rudder 15 Easy Hinges Notes Before Beginning Construction Any references to right or left refers to your right or left as if you were seated in the cockpit To build good flying models you need a good straight building board Crooked models don t fly well The building board can be a table a workbench a reject door core from the lumber yar...

Page 6: ...ng ribs to the spars and trailing edge sheeting b Place scraps of 1 16 balsa near the main spar to accurately space the W 1 wing ribs up from the building board The spacing is required for the center sheeting to be added later c Use the dihedral guage side of the die cut Dual Tool to set the root W 1 rib at the proper dihedral angle before gluing it in place Add the two remaining W 1 ribs 3 a Glue...

Page 7: ... step Otherwise you may find it difficulf to remove your wing from the board later 6 Pieces for the top center sheeting should be cut from the 1 16 x3 x30 balsa provided in the kit Again Sig Bond is recommended for the front and rear edges of the sheeting to make it easier to sand the joints smooth Also use Sig Bond on the center W 1 rib The sheeting can be glued to the ribs on each end using CA 7...

Page 8: ...own in the photo Using a modeling knife carefully cut out the outlined area This step accomplishes two things First it clears an area for the aileron servo and second it provides an open area between the main wing spars for the dihedral brace 14 Repeat steps 1 through 13 to build the opposite wing half Joining The Wing Panels 15 a Trial fit the two wing halves with the dihedral brace installed bet...

Page 9: ...ue in the brass bearings The outer end of the bearings should be even with the outer end of the blocks 18 a Glue the torque rod block assemblies in place on the wing T E again being very careful not to get any glue in the bearings b Notch the balsa trailing edge just forward of the notches in the torque rod blocks to allow full movement of the torque rods c Sand the top of the basswood blocks to m...

Page 10: ...A will help fill in the weave of the fiberglass resulting in a smoother surface Rub the second coat with your finger protected with plastic wrap keep it moving to smooth out the glue Use a fan to keep the CA fumes away from your face 4 When dry sand lightly to remove any rough spots Try not to sand into the fiberglass tape itself Ailerons 23 Sand the trailing edge of the aileron round and bevel th...

Page 11: ... the engine mounts To avoid any conflict drill a 1 4 dia relief partially through the back of the mounts at each hole 28 Position your engine on the mounts far enough forward for the propeller to clear the fuselage cheeks and mark the engine mounting holes Remove the mounts then drill at the marks with a bit that s just large enough to clear your engine mounting bolts When the time comes to fasten...

Page 12: ...he correct angle 35 a Glue the three 3 16 x1 4 x18 balsa fuselage stringers in place b When dry trim off the front of the stringers flush with the front of HR 36 a Bevel the top edge of the fuselage sides with a sanding block to provide a firm seat for the fuselage top deck when it is installed Notice that the angle between the top deck and the fuselage sides varies along the entire length Don t w...

Page 13: ...to the wing dowel and W 1 wing ribs by working through the opening in the bottom of the wing Be careful not to allow the glue to run down and bond the dowel to F 2 e When dry remove the wing and fill any gaps around the dowel with another application of glue 42 a The 1 4 x3 4 x1 basswood wing hold down blocks key into the notches in the fuselage doubler To accurately fit them temporarily tape or p...

Page 14: ...e outside of the fuselage b Install the die cut Lite Ply stab support so that it is flush with the top of the fuselage sides c When dry sand the Tee Lock tabs on the stab support flush with the fuselage sides 48 a The nylon pushrods must be supported at each former to keep them from flexing under load Use the die cut Lite ply pushrod straps F 3S and F 4S to support the pushrods Notice that the pus...

Page 15: ...both of them at the tips until they match perfectly The tips can be left square or sanded round if you prefer 55 a Sand the pre cut 3 16 balsa fin leading edge round b Sand the trailing edge of the pre cut 3 16 balsa rudder round c Draw a hinge line centered on the leading edge of the rudder Bevel the L E using the hinge line as a guide d Sand a notch in the rudder leading edge to clear the elevat...

Page 16: ...n the wingtips run the covering material around the corner about 1 8 Later when the main top and bottom covering pieces are applied they will overlap the wingtip covering and can be trimmed at the wingtip corners leaving a virtually invisible seam Extend the covering material about 1 8 past the outside edges of the hold down plates again to provide an area for overlap Cover the main portion of the...

Page 17: ...58 Using a No 11 X Acto blade or similar cut slots approximately 1 2 in depth and slightly wider than the hinges Cut eight slots in the stabilizer and eight matching slots in the elevators at the locations shown on the plans 59 After all of the slots have been cut insert EASY HINGES halfway into the stabilizer slots DO NOT GLUE THE HINGES YET Next carefully slide the elevators onto the hinges You ...

Page 18: ...e the stabilizer to the fuselage using Kwik Set epoxy Recheck its alignment and adjust as necessary before the glue dries 66 a Cut away a 3 16 wide strip of material from the center of the stabilizer where the fin is to be glued Epoxy the fin to the top of the stabilizer using a triangle to check its alignment as it dries Make certain that the back edge of the fin is lined up with the back edge of...

Page 19: ...nded that you go through the Pre Flight Checklist in Chapter 7 carefully before attempting to fly Engine And Fuel Tank Installation Engine installation on the FOUR STAR 40 is simply a matter of bolting the engine mounts that were prepared in step 28 to F 1 then bolting your engine to the mounts Finish installing the throttle cable which was partially prepared in step 51 by soldering the connector ...

Page 20: ...ioning Guide to set the ailerons in neutral as shown on the plans When you get to the field don t be surprised if the elevator and rudder are suddenly misaligned Temperature and humidity changes can cause the nylon push rod tubes to expand or contract slightly Use the trim levers on the transmitter to reneutralize the control surfaces and do the final trimming in the air The control surface moveme...

Page 21: ... back increases its sensitivity to control inputs but if carried too far the model can become completely unstable and uncontrollable The balance range shown on the plans is a safe area to use for test flights Don t exceed the rearward limit unless you are a very experienced pilot When landing the FOUR STAR 40 may tend to float a bit more than other models you have flown in the past so be ready to ...

Page 22: ...pm Central Copyright SIG Mfg Co Inc SIG MFG CO INC Montezuma Iowa 50171 0520 LIMIT OF LIABILITY In use of our products Sig Mfg Co s only obligation shall be to replace such quantity of the product proven to be defective User shall determine the suitability of the product for his or her intended use and shall assume all risk and liability in connection therewith ...

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