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. 

Fuselage Construction

 
25.

 

a. Tape the fuselage plans to the work bench and cover with waxed paper.  
b. The fuselage sides are assembled from two laser cut pieces. Align the fuselage front and rear pieces directly over 

the plan, check the fit of the parts, adjust if necessary and apply MEDIUM CA to the splice joint. Join another set of 
pieces for the other fuselage side.  

c. Glue the laser cut fuselage doublers to the fuselage sides with THICK CA or KWIK-SET-SET-Set epoxy. 

NOTE: Be sure to make one LEFT side and one RIGHT side. 

 
26.

 

a. Assemble all the fuselage formers (F-1 through F-6) into place between the fuselage sides. Put a rubber band 

around the fuselage at each former location to hold everything together.  

b. Slide the laser-cut lite-ply Fuselage Bottom Rear (FBR) under the rubber bands until it snaps into proper location 

between the fuselage sides. Do the same thing for the laser cut lite-ply Fuselage Top (FT) and the laser-cut lite-ply 
Stab Support. 
NOTE: The "Tee-Lock"tabs on the formers, FBR, and FT are made over-sized to protrude past the fuselage sides. 
These will be sanded off after the fuselage has been completely assembled. 

 

 

 

 
27.

 

a. Place the fuselage over the top view on the plans to check the alignment. Even if some of the plywood is badly 

warped, the interlocking parts are designed to be self-aligning - warps in individual pieces should cancel out. If there 
are any persistent warps or twists, now is the time to fix it! Once the fuselage is glued, it can't be realigned. Double 
check that the opening at the back end of the fuselage is square 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. Start with small 

patches of glue in the corners, checking the fuselage alignment as you go. Keep applying glue until the complete 
inside of the fuselage has been gone over once. Now go back and glue all of the joints on both sides. Leave the 
rubber bands and tape in place until all of the glue has cured completely. 

 
28.

 
Locate the laser cut lite-ply headrest (HR) on top of FT and glue HR in place. Use 
the 29° side of the Dual Tool to get the correct angle between HR and FT.

 

 
29.

 

a. Position top formers F-4T and F-5T in the correct slots in FT and glue.  
b. Glue the five 1/8"x5/16"x24" balsa fuselage stringers into the fuselage top 

formers and the headrest. Note that the top stringer and the two bottom 
stringers sit in notches in F-6, while the two middle stringers butt against 
the front face of F-6.  

c. When the glue has cured, trim off the front of the stringers flush with the 

front of HR and the back of F-6. Savaothe scrap stringer material for later 
use. 

 
30.

 

a. Install the landing gear plate to the fuselage by gluing it to the sides, the 

doublers, and the bottom of F-2. Don't be stingy with the glue - you may 
find yourself picking up the landing gear as a separate piece after a hard 
landing.  

b. Glue the fuselage bottom front (FBF) in place using MEDIUM or THICK 

CA. Be sure to glue the joint between FBF and the landing gear plate from 
inside the fuselage. 

Содержание 4-STAR 60

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

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

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