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TufFlight 4D Manual

Amazing 3d capability - plus outstanding durability
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The Toughest R/C Planes Ever!
48"
Wingspan:
Length:
38"
4.25 - 4.75 lbs
Weight:
Engine:
.63-.82 four stroke
Radio:
4 channels
5
Servos:
Wing Area: 720 sq in
nominal 200 sq in
Side Area:
Hello, and thanks for buying the 4D! Whether you've just entered the exciting world of 3D flying, or a seasoned
veteran, the 4D is the perfect combination of agility, durability, versatility and value.
Caution: The 4D is not intended as an R/C trainer airplane. This plane is a very agile aerobatic performer that is
capable of quick rolls, hovering flight and many tricks appealing to the "3D" flyer.
The CG location is 5" from the leading edge. Move rearward as desired for easier 3D
Note: If you want to fly slow AND fast, be sure to install tail counterbalances shown at end of manual.
While you may be tempted to fly close to yourself, please practice in a safe manner.
Please read and understand the instructions before starting to build. We recommend joining the AMA and follow-
ing the AMA safety code. Call 1 (800) I- FLY-AMA for more details.
We assume no responsibility for how you use your plane. That said, let's get started!
Items Included in kit:
Wing:
Pre sliced foam cores
(2) 3" x 24" pre cut corplast ailerons
(4) Robart Hinge points
Braces:
(2) 1/2" x 1" x 5-7/8" engine mount beams
(1) 3/16"" x 2" x 9" engine plate
(4) 1/16" x 3/4" x 5" support plates
(1) 1/16" x 1-1/2" x 5" fuse key plate
(1) 0.040" x 1-5/16" x 48" brace material
(1) 0.040" x 1-5/16" x 24" brace doubler
(1) 0.060" x 1-3/8" x 8" soft plastic sheet
This Instruction Manual
Template Plot Sheet
3/16" formed landing gear
Rev 2.7
5376 Amalfi Drive,
.40 - .53 two stroke,
Amazing 3D capability
Outstanding Durability
Always obey safety rules and do not exceed your abilities.
Clay, NY 13041
-plus-
Fuselage, Tail Feathers and Fins:
(1) machined plastic fuselage (the bat)
(1) pre-drilled 7/8" wood axle dowel
(1) 3/16" x 10.5" carbon tube axle
(1) 3/16" x 18.5" carbon tube axle
(2) 7/32" x 2-1/2" brass axle sleeve
(2) 12" x 24" corplast sheets
(8) wooden skewers
(2) 3" blue skewer guide tubes
Hardware:
(4) 1/4-20 x 1.5" nylon bolts
(10) 1/4-20 nuts
(2) large washers
(4) 14" zip ties
(6) 3/16" wheel collars
(1) 7" x 1/16" tail skid wire
12" thin copper wire
www.tufflight.com
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Summary of Contents for TufFlight 4D

  • Page 1 4D is the perfect combination of agility, durability, versatility and value. Caution: The 4D is not intended as an R/C trainer airplane. This plane is a very agile aerobatic performer that is capable of quick rolls, hovering flight and many tricks appealing to the “3D” flyer.

  • Page 2: Items Needed To Complete

    Items needed to complete: Helpful Tools: 40 grit sandpaper on block Equipment: (available at auto finishing stores .46-.53 two stroke engine and Sears) or .63-.82 four stroke hobby knife / utility knife radio receiver soldering iron 6” aileron extension rat tail file (used as battery switch/charging) square battery: 600 mAH...
  • Page 3 Glues Needed: You will need these glues to assemble your plane. Please do not substitute! CA (cyanoacrylate) - either medium or thin viscosity. Only a small amount needed. 5 minute epoxy : only a small amount needed. 10 or 30 minute may be used if you’re patient. Elmers Ultimate Polyurethane Glue - high strength, light weight, expands while curing to penetrate and fill voids.
  • Page 4 Prepare the foam and plastic wing pieces You’ll need : foam core pieces 40 grit sandpaper on block clear plastic braces, engine plate 3M Spray glue, hobby or utility knife masking tape, marker, ruler Step 1: Gather parts and tools Step 6: Remove film from clear plastic braces Step 2: Carefully separate foam pieces...
  • Page 5 Step 11: Mark the 24” brace doubler in the Step 16: Discard the 3rd piece. Only two center 4” pieces are used Step 12: Mark left over 12” piece 4” from Step 17: Draw a line 1/4” from one edge one end the long way as shown.
  • Page 6 100 grit paper works well here Step 21: lightly scuff the 36” and 24” Step 26: Spray the root edges of the rear braces with sandpaper (both sides of each) cores with 3M77 Stretch tape tightly across the joint (top and bottom) Step 22: Locate the engine plate and mark Step 27: Tape the cores together with...
  • Page 7 apply a heavy coat of 3M77 Spray whole front edge (24” piece on top) Step 31: Spray the whole brace assembly Step 36: Spray the wing assembly front with 3M77 on the doubler side only edge again as shown Step 32: Spray the wing assembly front Step 37: Remove masking tape from “no edge as shown spray zone”...
  • Page 8 Goop where plate sits in foam slots (see next step) Step 41: Apply Goop to top and bottom Step 46: Apply Goop to edges of 5” surfaces 2” from each end support plate Double check hole location (closer to front!) Step 42: Insert engine plate into slots as Step 47: Set the support plate at the angle shown...
  • Page 9 Be sure support plates remain in correct alignment (under tape). Tape or clamp plates as necessary to be sure fillets are smooth and will dry to strong joints Step 51: Stretch tape as shown. Monitor Step 56: Insert key plate the fit of the support plates.
  • Page 10 Be careful not to distort the wing! Step 61: Use lightweight clamps to hold Step 66: Sand corners of plate round the plates together while Goop cures. Prepare misc pieces while Goop cures Be sure to make left and right You’ll need : 2 remaining 5”...
  • Page 11 Be careful to make the line centered on one flute Step 71: Extend the axle location marks Step 76: Cut relief for brass axle tube as along the whole piece of corplast shown Use only a VERY LIGHT mist coat! line up the axle location of the template with the line...
  • Page 12 non scale tail This step not needed for feathers shown Scale Elevator style. Step 81: Trim flutes from “fresh edge” as Step 86: Repeat 81-85 for other elevator before. This will be the elevator LE half. perform this step to avoid crushing the For Scale Elevator corplast when...
  • Page 13 Don’t crush corplast! mark this flute along it’s whole Optional: length You can still go back and glue some wood filler in (lift up paper flutes if you DO crush it after you mark too much which flute it is) Step 91: Be careful NOT to overtighten Step 96: Align template as shown so arrow screws...
  • Page 14 Assemble fuselage You’ll need : machined “bat” with filler dowel epoxy, Goop, brass axle tubes, marker 1/4” drill, knife, tape measure(s) 100 grit sandpaper, rat tail file wing assembly, long dowel, alcohol Step 101: Gather parts and tools Step 106: Roughen up brass tube Be sure to re-align using your mark! Proceed quickly to...
  • Page 15 Step 111: Measure and mark fuse plates Step 116: Use the marks on the plates and 13/16” from wing center as shown measure from tips to align bat in place Be sure the bat is straight in both YAW (ie, aligned as in above picture, and Don’t go all the way PITCH axes for this step)
  • Page 16 Note Elevator and Rudder tube angle slightly to the locations left as shown (see step 123) Elevator - right side Rudder - left side as installed on plane Step 121: Use rat tailed file to get a nice Step 126: View looking inside the bat angled exit for the nyrod housing (shown bottom side up) Twist the tubes and...
  • Page 17 use square to insure hole is perpendicular to wing as shown Step 131: Poke hole through wing behind Step 136: Mark plate locations on wing brace at wing center and insert blue tube bottom as shown Optional: inset This will be plates flush with used as a wing surface by...
  • Page 18 Use the largest servo arms you have for all controls (you can adjust them later) Step 141: Gather radio parts and choose Step 146: Mark the wing TE 14” from the servos for each function left tip. This way is the The aileron control easiest, but if you horns will lie 14”...
  • Page 19 Wing bottom showing traced layouts of all servos (except throttle, which will be drawn on top) Step 151: Repeat for left aileron servo. Step 156: Step omitted battery goes in left wing bottom Step 152: Mark the battery location shown Step 157: Step omitted Use these positions if...
  • Page 20 Servo should lie EXACTLY halfway into depth of wing. Step 161: Carefully rout out the servo Step 166: Locate location of “hole X” (now depth with a Dremel tool exposed in servo cavity) Servo tops should be flush with wing surface (or as close as possible Also make a notch if bottoms poke through...
  • Page 21 A 6” aileron Wrap battery extension is used also if desired as a plug in switch from battery to RX Step 171: Poke a hole from the bottom to Step 176: Optional : tape servo case with top near the battery for the battery plug masking tape to protect from glue Step 172: Pull the battery plug through the Step 177: Spray servo cavity with water...
  • Page 22 Step 181: Spray the battery and cavity Step 186: Close up showing aileron servo with water and glue in place with poly U wire treatment Step 182: Glue the aileron servos in place Step 187: Make scrap rectangles of foam to with water and poly U fit cavities above aileron servos and battery Step 183: Glue throttle servo likewise.
  • Page 23 Assemble tail feathers on fuselage You’ll need : fuselage “bat” assembly corplast tail feathers, carbon tube axles 2-56 push rods, clevises, inner nyrod tubes silver solder, flux, soldering iron, holding jig pliers, copper wire, bending template plot Step 191: Now apply Goop to one side of Step 196: Gather tools and materials the fuel tank plates axle shown as...
  • Page 24 Step 201: Step omitted Step 206: step omitted Step 202: step omitted Step 207: Screw 3” threaded rudder push rod link onto 22” rudder nyrod Step 203: step omitted Step 208: Install jam nut and clevis Adjust clevis position on try to push the horn to suit your desired elevators to center...
  • Page 25 (Not shown: 16” nyrod installed into it’s housing) Step 211: Sand push rod ends to clean Step 216: Install nyrod to elevator linkage. Bend rods to give clearance as shown Use the 3rd hole from the surface for best results. Don’t use all the To get radical control, copper wire!
  • Page 26 Step 221: Trim rear blue tube close to wing Step 226: Mark LE center as shown at surface using razor saw (top and bottom) engine plate Sand all blue tube ends flush after sawing Step 222: Trim front tube as well (both top Step 227: scribe center line along LE as and bottom) shown...
  • Page 27 It’s beneficial to use a single piece of An acid brush covering per side works well but a paper towel corner also works Step 231: Spray some 3M77 into a cup Step 236: Lay wing over covering to and smear around receiver cavity edges determine size needed Step 232: Apply a strip of packing tape over Step 237: Cut covering oversize leaving a...
  • Page 28 Step 241: Spray engine plate area with Step 246: Pull covering around edges and 3M77 iron down. Trim excess. Step 242: Push covering into corners with Step 247: Spray wing bottom with 3M77 popsicle stick Step 243: Set your covering iron at 250 to Step 248: Spray wing leading edge area 300 degrees F with 3M77...
  • Page 29 Wait until 3M77 dries a little before applying covering. This way you can reposition it easier, and the adhesive will be re- activated by the heat of your iron anyway when the covering is in the final position. Step 251: Apply covering so it wraps Step 256: Trim covering at edges leaving around wing LE as shown some overlap...
  • Page 30 Find and poke rear tube holes with skewer Step 261: Iron covering to wing tips and Step 266: Use a skewer to locate and poke trim holes where pre-drilled. Step 262: Apply a patch where battery Step 267: Poke fuse plate holes as shown cable pokes through top covering Step 263: Expose switch charging jack with Step 268: Poke front tube, engine plate,...
  • Page 31 Step 271: Seal covering to hole edges with Step 276: Drill holes in corplast as shown soldering iron if desired. about 1” deep Install pull pull setup for ailerons just press fit -- no You’ll need : covered wing, corplast ailerons glue needed marker, ruler, punch, hinge points scrap corplast, poly U glue, water...
  • Page 32 Step 281: Install aileron as shown with Step 286: trim tape even with aileron at two shims on each end to set spacing root Frost King # T94 is excellent hinge tape! Walmart sells a 2” x 25’ roll for under $5 Step 282: Remove shims, but take care not Step 287: trim tape even with aileron at to disturb aileron.
  • Page 33 Note how top and bottom tape touch together. Work hinge back and forth and check for free movement Step 291: Close up view of hinge pressed Step 296: Clip excess screw length and together. Keep centered along length lock nuts in place with CA. Thin copper wire is a good tool (left over from silver...
  • Page 34 Centering the ailerons is easy -- just slide the line through the servo arm when your trim is zero Step 301: Tie a knot and CA as shown Step 306: Turn on radio and zero the aileron trim.. Pull / push the line to center ailerons Careful not to get CA down into moving parts.
  • Page 35 Install fuselage on wing You’ll need : wing assembly, wheel collars fuel tank fuselage / tail assembly, fins, skewers zip ties, wire cutters, pliers, push rods servo arms, screws, tail skid wire, marker tape measure, knife, screwdriver Step 311: Gather parts and tools Step 316: Check fuselage alignment once again.
  • Page 36 Step 321: Use a skewer to poke holes for Step 326: Enlarge holes in servo arms with zip ties behind key plate as shown #49 drill for the push rods. Step 322: Trim zip tie end to a point so Step 327: Cut 3”...
  • Page 37 Step 331: Bend angle in short push rod as Step 336: screw pushs rod into nyrods shown Step 332: Turn on radio and zero trims for Step 337: Mount servo arms with push rudder and elevator for following steps rods as shown Step 333: hold elevator at neutral while Step 338: Make first bend in 7”...
  • Page 38 For Non-Scale no need to make Fuselage: these very tight Wheel collars will Tighten just embed in fins and enough so tank lock them in place on won’t slide skewers Step 341: tighten zip ties Step 346: mark locations for 4 wheel collars which install on the front and rear skewers For Scale Fuselage: Choose closest flutes...
  • Page 39 Balance the plane with engine installation You’ll need : assembled plane, engine mount beams engine, muffler, spinner, prop mounting hardware, throttle push rods fuel tubing, landing gear, wheels, collars ruler, marker, 1/4-20 bolts, nuts, washers rubber band, drill, 8" soft plastic sheet Step 351: Gather parts and tools Step 356: Mark CG locations 5”...
  • Page 40 Step 361: Trim excess beam material at Step 366: cut a piece of fuel tubing to slip front with band saw or similar over both throttle push rods to join them Step 362: check fit of throttle push rod in Step 367: this slip fit servo saver stops your throttle arm and adjust as needed from stripping gears in a bad crash...
  • Page 41 Step 371: adjust aileron linkage to provide Step 376: Trim as shown. Remove from your desired throw. vise and apply medium CA and kick it. Install Tail Counterbalances if desired These will allow you to fly FAST for BOTH 3D and FAST sport flying You’ll need : (3) 2-56 threaded rods, (6) 1/4-20 nuts pliers, tape, CA, kicker, vise (desireable), wire cutters, hammer, ruler, pencil...
  • Page 42 Figure 1 Notes on Contol Travel Adjustment: It’s normally best to use the 3rd hole from the pivot end of the horn of the Dubro nylon “T Style” horns, and NO CLOSER. Be sure your radio is programmed to take advantage of the entire servo range -- use your travel adjust setting to achieve this.
  • Page 43 Note on the Durable Engine Mount Beams: The 4D engine mount beams are made of an almost indestructible material that behave like steel. Upon installation or after a crash they can be bent back into a straight part time after time, using a vise and pliers or similar (they will NOT crack).
  • Page 44 Also look for these from TufFlight: The 4D-Lite: Our first ELECTRIC powered kit. Indoor/outdoor super lightweight and durable. Fly an entire 3D airshow in your front yard. One day build time. Fully 3D capable deluxe kit versions available so you supply only your radio RX.