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Table of Contents
- 1 Locate and Prepare
- 2 Adhesives
- 3 Fuselage Assembly
- 4 Assembling the Registration Pins
- 5 Locate the Firewall Sections
- 6 Trike Version Only
- 7 Stabilizer Assembly
- 8 Elevator Assembly
- 9 Rudder Assembly
- 10 Vertical Fin Assembly
- 11 Wing Joiner Platform Assembly
- 12 Wing Assembly
- 13 Flap Assembly
- 14 Hardware Key
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Table of Contents
Related Manuals for Hobby-Lobby Telemaster 40 Deluxe
Summary of Contents for Hobby-Lobby Telemaster 40 Deluxe
- Page 1 Telemaster 40 Deluxe Assembly Manual Hobby Lobby International 5614 Franklin Pike Circle Brentwood TN 37027 USA Phone 866-512-1444 MADE IN THE USA...
- Page 3 Terminology used in this manual. With the precision of laser cut parts and notch and tab construction, the assembly and gluing sequence becomes very important. If components are glued in place to soon, they will not allow enough move- ment to install other components. When instructed to install a part, do only that. You will be instructed to glue it when it is no longer required to be moveable.
- Page 4 Your Telemaster kit can be constructed with several options. You can build it as a standard gear (tail dragger), the classic Telemaster stance or a more modern tricycle gear model. You can also build either of these to accommodate the Telemaster Float kit for operation off of water. As you progress through the assembly procedures we will point out the various deviations from the basic standard gear configuration.
- Page 5 TRIKE VERSION ONLY A. Locate NGNP and install four #4-40 blind nuts. B. Install and glue three NGMB into FW-A in the slots provided. Use Epoxy or PU glue for this. C. Install and glue NGNP to the three NGMB parts, the blind nuts should be on the side facing FW-A.
- Page 6 We will now start the fuselage side sub- assemblies; make sure you make a left and a right side. Place one of the fuse- lage sides on the registration pins using holes A and D. Slide FD down the pins to test fit.
- Page 7 c 9 Locate four ¼” x ¼” x 36” sticks, they will be glued into each corner of the fuselage aft section. Start with one stick butted up against FD. Note that the stick must be glued in line with the inner notches. This stick will terminate at and to include F9.
- Page 8 c 13 Install two 1/4” x 20 blind nuts into FWBP. c 14 The first glue up of the fuselage will con- sist of the firewall assembly FW-A&B, the fuselage floor FF, the F2 assembly, F3, F4, the wing bolt plate FWBP, the hatch mounting plate FHMP and the servo tray FST.
- Page 9 Install and glue F5, F6 and F7. Install c 17 each former into the notches on one side and then tip into the other side. BELOW: The landing gear assembly is ready to be installed into the fuselage. The word UP refers to its position in the fuse- lage, the nuts must be facing the inside of the fuselage.
- Page 10 Place the remaining magnet near the one c 21 installed in FHMP and let them join. Mark the top of the top magnet with a magic marker. Locate the hatch components FHA and two FHA-H. Place the FHA on the bench with the labeled side down and install the remaining magnet in the hole provided with the side you just marked facing down.
- Page 11 c 24 Place the hatch cover assembly onto the fuselage and install and glue the ¾” x 4” triangle stock onto the hatch cover. This should butt snugly up against the 3/8” tri- angle stock installed in step 21. BELOW: Clamps and tape secure the sides tightly to the top as the adhesive cures, use this same method when installing the fuselage bottom.
- Page 12 Install and glue the nose filler pieces NF. c 30 c 31 If you are building the trike version, now is a good time to install and adjust the nose gear steering cable. Note that a ball link is used on the steering tiller arm. c 32 Locate and prepare the five electric mo- tor mount parts, MMA, MMB, MMH, MMV...
- Page 13 STABILIZER ASSEMBLY Cover the stabilizer plans with parchment or waxed paper. Prepare the stabilizer plate (SP). Install four #4-40 blind nuts into the holes provided. They should be installed from the top. Pin this part in place over the plans. Place the pins through the blind nuts to keep them out of the way.
- Page 14 Install the top spar from 1/8” X 1/2” c 10 basswood stock. Taper the ends to butt fit to the stabilizer tips SWT. When your satisfied with the fit of this bevel, glue the top spar into position. c 11 Note that at the center of the false trail- ing edge and false leading edge there is a low spot.
- Page 15 c 13 Install and glue the trailing edge STE. The center notch will determine position. c 14 Install and glue the leading edge SLE. The center notch will determine position. c 15 Use a plane and sanding bar to shape the leading and trailing edges of the stabilizer. Sand all surfaces as required in preparation for covering.
- Page 16 Sand the rudder assembly flat and then c 22 round off the trailing edge. Extend the hinge slots into R1 and slightly bevel both sides of the assembly to allow for move- ment when installed. This concludes the rudder assembly Vertical Fin assembly Laminate the two V1 using the register pins.
- Page 17 c 5 Install and glue WP-FLE to the leading edge of WP. c 6 Use Epoxy or thick CA to install and glue WP-1A to WJ, WP and WP-FLE. c 7 Install and glue WP-1B to WJ and WP. c 8 Install WP-B1 and WP-B2. c 9 Install and glue rib WP-2 on both sides of SP.
- Page 18 c 15 Use the register pins to position the top sheeting and glue it into position. Use tape or weights to hold it in position until the adhesive has set. c 16 Install and glue WP-LE into position on the leading edge. c 17 Plane and sand LE to contour with the ribs.
- Page 19 c 5 Prepare TE, TES and TESB. Note that the notches in TESB are 1/4” deep on one side and 3/16” deep on the other. Place it on the bench with the 1/4” side facing you. Install and glue TES in the front (3/16”) notches.
- Page 20 c 11 Slide SW-T down into the slots just be- hind SW-B. Use finesse not force, when everything is lined correctly they will fall in place. IMPORTANT next we will tack glue SW-T and SW-B together capturing all ribs from W4 through W12 however it is very important that SW-T and SW-B be exactly aligned before applying glue.
- Page 21 c 16 Install the top spar flange SPF-T. Apply glue to the top of the sheer webs from W12 to the root and to each rib in the flange notch at the top of each rib. Place SPF-T onto the wing and use a straight edge to weigh it down until it cures.
- Page 22 c 22 Use slow CA, apply a liberal bead to the top of the spar flange the full length in- cluding the tip section of the sheer webs. We will glue it to the ribs and the leading edge from the bottom later. Install LES-T and hold in place with a straight edge until cured.
- Page 23 Install and glue two wing sheeting gus- c 32 sets WGS. These will install at the wing tip at the corners of W12 and TES and W12 and the bottom spar flange SPF-B. These will support the wing tip sheeting and should be glued in flush with the bot- tom of W12.
- Page 24 c 4 Carefully align the slot in the flap hard point block (FLHPB) with the slot in FLHP and glue in place. Before installing the top sheet, the lead- ing and trailing edges as well as FLHPB must be sanded to contour with the flap ribs.
- Page 25 Part # Qty. Sheet # SIZE Material Description 1/16” X 2-2/2” X 4” AC PLY Anti crush plate 3/32” X 4” X 48 AC PLY Aileron horn 1/16” X 6” X 36” BALSA Bottom center sheeting, wing 1/16” X 4” X 36” BALSA Bottom leading edge sheeting, wing 1/16”...
- Page 26 Part# Qty. Sheet# Size Material Description 1/4” X 5” X 12” LPLY Gear brace 1/4” X 4” X 7” BASSWOOD Horn block 1/8” X 3” X 36” BALSA Horn block filler 1/4” X 3” X 36” BALSA Leading edge, wing LES-T 1/16”...
- Page 27 Part# Qty. Sheet# Size Material Description 1/4” X 4” X 36” BALSA Stabilizer trailing edge 1/8” X 4” X 36” BALSA Stabilizer top spar 1/16” X 6” X 36” BALSA Wing top center sheeting 1/4” X 3” X 36” BALSA Wing trailing edge 3/16”...
- Page 28 Part# Qty. Sheet# Size Material Description 1/8” X 12” X 48” LPLY Wing platform WP-1A 1/8” X 12” X 12” AC PLY Wing platform part A WP-1B 1/8” X 4” X 36” BALSA Wing platform part B WP-2 3/32” X 3” X 36” BALSA Wing platform part 2 WP-B1...
- Page 30 Hobby Lobby International 5614 Franklin Pike Circle Brentwood TN 37027 USA Phone 866-512-1444...
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