SIG FOUR-STAR 60, Assembly Manual, Page: 6 / 18

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6) Place the 4-40 Solder R/C Link into the last hole in the
control horn. Swing the aileron pushrod against the control horn.
Make sure that the servo is still in the neutral position and tape the
aileron into approximately neutral position.
Hold the pushrod
against the 4-40 Solder R/C Link. Mark the pushrod wire 3/16”
beyond the end of the center barrel of the solder link.
NOTE: Depending on the type of servo that you use, you may
have to bend the pushrod slightly in the middle to angle it up from
the wing so that it is aligned with the control horn without putting
any bending force on the servo arm.
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7) Remove the pushrod from the servo and remove the solder
link from the control horn. Cut the pushrod at the mark. Slip the
solder link onto the end of the pushrod so that the end of the rod
extends 3/16” beyond the barrel on the link and solder into
position, using enough heat to “sweat” the joint completely.
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8) Reattach the pushrod to the servo and the control horn.
The aileron should be approximately neutral. Final adjustment will
come later. Now fabricate and install the opposite pushrod and
control horn assembly the same way.
Joining the Wings:
For the following steps you will need:
• Both wing panels
• 1 each 12mm Hardwood Front Wing Joiner
• 1 each 6mm Plywood Rear Wing Joiner.
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1) Slide the front and rear wing joiners into one of the wing
panels and then, slide the other wing panel into position to test the
fit of the joiners. The wings should fit tightly together and the
center ribs should fit flush around their edges. If you need to make
any adjustments to get the proper alignment you may slightly trim
the openings in the wing ribs.
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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 joiners. 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.
Fitting the Wing to the Fuselage:
For the following steps you will need:
• The assembled wing
• The fuselage.
• 2 each 1/4-20 x 1-1/2” Nylon Wing Bolts
• 2 each 2mm Plywood Wing Hold-Down Plates
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1) Place the plywood wing hold down plates on the bottom of
the wing. The 1/4” holes in the plates should line up with the holes
in the wing panels. The rear edges should be flush with the wing
trailing edge and they should be centered on the wing joint.
Carefully draw around the plywood plates with a felt tip pen to mark
their location on the wing covering. Lift the plates from the wing.
3/16”