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SIG Four-Star 40 SIGRC44 Building And Flying Instructions

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  • Page 2: Design Philosophy

    To simplify matters, most glues can be classified as one of four basic types: 1. Fast cyanoacrylate adhesives (abbreviated in this book as "CA") such as SIG CA, Hot Stuff, Jet, etc ... 2. Easy-to-use water-based glues such as SIG-BOND (yellow) and SIG SUPER-WELD (white).

  • Page 3: Radio Requirements

    CA. An accelerator spray and debonder are also available and are described below. Sig CA Thin - Watery in consistency, thin CA should only be used when the two parts to be joined are in perfect contact with zero gap.
  • Page 4 You'll Need a Good Sanding Block An assortment of different size sanding blocks are indispensable tools for model construction. A good general purpose block can be made by wrapping a 9"x11" sheet of sandpaper around a piece of hardwood or plywood.
  • Page 5 Sawn Birch Plywood 2 1/16"x3/4"x1-5/8" Wing 1 1/4"x1-1/2"x3" Landing Hold Down Plates Gear Mount Hardwood I 1/4" dia.x2" BIRCH; 2 1/4"x1/4"x2" 2 1/4"x3/4"x1" BASSWOOD; 4 3/16"x3/8"x30" SPRUCE; Main Wing Hold Down Dowel BASSWOOD; Grooved Wing Hold Down Blocks Wing Spars Torque Rod Blocks Formed Wire Parts 1 1/16"...

  • Page 6: Wing Construction

    Add the 1/16"x1-1/4"x30" top trailing edge sheeting. For this step it is recommended that you use Sig-Bond (aliphatic resin) along the back edge of the sheeting that glues to the trailing edge. That will make the joint easier to...
  • Page 7 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.

  • Page 8: Joining The Wing Panels

    11. Carefully carve the top of the trailing edge to match the slope of the top T.E. sheeting using an X-Acto #26 whittling blade. Wrap the top of the blade with masking tape (to protect the sheeting), leaving about 1/2" exposed at the base. Use the masked portion to guide the blade at the corred angle.

  • Page 9: Finishing The Wing

    a. When dry, double check through the servo opening on top and the center sheeting opening on the bottom that the dihedral brace is glued solidly to the main wing spars and the W-1 wing ribs. b. Glue the die-cut balsa piece BP into the aft end of the servo opening. When dry, trim BP flush with the top center sheeting.
  • Page 10 METHOD 1: METHOD 2: (Shown in the photo) 1. Coat the wing center joint with slow- 1. Cut the tape to length, then lightly spray one side with a spray drying epoxy glue. adhesive (such as 3M "77"). 2. Lay the tape on top of the glue. 2.

  • Page 11: Fuselage Construction

    FUSELAGE CONSTRUCTION Before starting fuselage construction, there are a few subassemblies that should be built and set aside until needed. This is done to avoid interruptions during the flow of fuselage construction. Fuselage Subassemblies a. Glue together the two die-cut plywood F-1 pieces using KwikSet Epoxy or slow CA.
  • Page 12 Basic Fuselage Construction a. Tape or rubber band the fuselage sides together at the rear. b. Working from the rear forward, slip all the fuselage formers (F-6 thru F-1) into place. Put a rubber band around the fuselage at each former location to hold it tightly together.

  • Page 13: Mounting The Wing To The Fuselage

    39. The fuselage is now ready for final sanding. Sand off all "Tee-Lock" tabs then round the bottom edges of the fuselage and the corners of the balsa top deck. Use a sanding block, starting with 80-grit sandpaper. Switch to 150-grit or 220-grit sandpaper for the final sanding.

  • Page 14: Servo And Pushrod Installation

    a. Remove the wing and tap the wing hold-down blocks with a 1/4-20 tap. You can apply a few drops of thin CA to the holes to strengthen the threads. b. Redrill the holes in the wing with a 1/4" drill bit to pass the nylon wing bolts. Servo And Pushrod Installation 45.

  • Page 15: Tail Surfaces

    50. With the pushrods hooked up to the servos, you can now glue F-3S and F-4S to the front of F-3 and F-4, respectively, in such a way to keep the bends at a minimum. 51. This is a good time to install the nylon outer tubing for the throttle pushrod. Temporarily mount your engine to help locate where the throttle pushrod will come through F-1.
  • Page 16 (glass) resin, sanded between coats. Finish off the engine area with a few coats of colored Sig Supercoat Dope.
  • Page 17 INSTALLING EASY HINGES Sig's famous EASY HINGES have been included with your kit to hinge all of the control surfaces. Each ultra-thin hinge is actually a three-part laminate - a tough plastic inner core sandwiched by an absorbant wicking material. They have been chemically treated to slow down the reaction of thin CA (which is normally instant), to allow the glue time to soakall the way to the ends of the hinge and into the wood surrounding it.

  • Page 18: Final Assembly

    63. The ailerons are hinged exactly like the tail surfaces, but the torque rods must be glued as well. Start by cutting the slots in the wing and the ailerons (four per aileron) and install EASY HINGES halfway into the ailerons. a.

  • Page 19: Engine And Fuel Tank Installation

    Like most Sig kits, the fuel tank in this model is installed from the rear of the fuel tank compartment rather than through a removable hatch. This choice was made for several reasons. A hatch opening makes the nose weaker and it's very difficult to keep oil from leaking in around a hatch.
  • Page 20 The nylon aileron connectors can be moved up or down the torque rods to adjust the amount of aileron throw. Tape the servo wire to the wing to keep it from getting tangled with the aileron servo, as well as the servos in the fuselage.
  • Page 21 R/C pilots wanting to fly your new SIG airplane! The top view and side view drawings are provided for modelers who wish to to develop their own personalized color and trim scheme for the FOUR-STAR 40.

  • Page 22: Limit Of Liability

    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...

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