Sportsman Aviation Giant Scale Corby Starlet Assembly Instructions Manual

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The Corby Starlet is the first post-war Australian designed single seat aircraft to fly in Australia. The Starlet was designed and built by John Corby and

Barrie Bishton of Sydney N.S.W. Australia. This design placed fourth in a world-wide design competition for small racing aircraft conducted by Rollason

LTD in England in 1964. The prototype Corby Starlet first flew on the 9th of August 1967 in the small country town of Camden. Unknown at the time

to the model designer (Chris White) the prototype Corby Starlet model also had its maiden flight at the same town of Camden nearly 38 years later.

The Full-Size Starlet was a semi-aerobatic sports airplane made of an all-wood construction. The fuselage is a combination of spruce longerons and

frames and is sheeted with plywood. The wing is a single-piece structure, consisting of a solid laminated spar and built-up ribs. The D-nose leading

edge is plywood covered. The remainder of the wing, including the ailerons, is open-structure and fabric covered. The main undercarriage consists

of spring-steel legs bolted to a stiffened frame in the fuselage, immediately behind the firewall. To this day many examples of this aircraft are flown in

countries all over the world.

Every attempt has been made to make the 38.5% model version of the Corby Starlet as scale as possible with only minor changes being made to

enhance flying characteristics. Indeed even the color scheme is modeled from a full size plane flying today. The prototype model was flown with a

Magnum XL-180RFS and the model is very well suited to this motor combination. Great care should be taken when setting up any new model and all

the travel throws and C/G should be measured and kept as close as possible to the recommended settings as described in the assembly instructions.

This will allow maximum flight performance with maximum enjoyment factor!

You will find the Giant Scale Corby Starlet very easy to take-off and land. Once you have some time under your belt, you can really wring-it-out

pushing the envelope even beyond the full-scale!

The Sportsman Aviation Giant Scale Corby Starlet ARF is distributed

exclusively in the USA by Global Hobby Distributors

and in Australia by Tates Performance Hobbies

Version 1 December 2006

scale: 38.5%

Wing span: 85.85 Inches (2181mm)

Weight rtf: 17.25 Pounds (7.8kg)

engine required: 1.80 Two-Stroke or 1.80 - 2.10 Four-Stroke

Made in China

ASSEMBLY INSTRUCTIONS

Wing area: 1455 Square Inches (93.8dm

Wing Loading: 27 Ounces/Square Foot (95gr/dm

features and specifications

Precision-Built, CAD-Designed Airframe for Light Weight and High Strength

Laser-Cut, Balsa and Plywood Construction

Premium Iron-On Covering in Detailed Scale Color Scheme

Aluminum Main Landing Gear Brackets and Tail Wheel Assembly

Prepainted Fiberglass Cowling, Wheel Pants and Clear Molded Canopy

Strong, Aluminum Adjustable Engine Mounting Beams

Dual Aileron Servos, Pull-Pull Rudder Cables and Reinforced Split Elevator Pushrod

Includes High-Quality Hardware

Fast and Easy Assembly - Over 100 High-Resolution Digital Photos and Drawings

)

radio required: 4-Channel or More w/5 High-Torque Ball Bearing Servos

Page

)

Length: 70.39 Inches (1788mm)

functions: Ailerons, Elevator, Rudder and Throttle

Kit product number 127533

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Summary of Contents for Sportsman Aviation Giant Scale Corby Starlet

Page 1 This will allow maximum flight performance with maximum enjoyment factor! You will find the Giant Scale Corby Starlet very easy to take-off and land. Once you have some time under your belt, you can really wring-it-out pushing the envelope even beyond the full-scale!
Page 2: Table Of Contents
Thank you for purchasing the Sportsman Aviation Giant Scale Corby Starlet ARF. We're confident that the quality of your new airplane meets and even exceeds your expectations. Before completing the final assembly of your new airplane, please carefully read through these assembly instructions in their entirety.
Page 3: Our Recommendations
WHat enGine sHouLd i use? The Giant Scale Corby Starlet ARF can be flown using either a 1.80 size two-stroke engine or a 1.80 - 2.10 size four-stroke engine. A 35cc - 40cc gasoline engine would work well, too. The airplane will fly great using any engine within the recommended size range, although for the best aerobatic performance we suggest using an engine toward the higher end of the suggested size range.
Page 4: Tools And Supplies Required
tooLs and suppLies reQuired ❑ 5 and 30 Minute Epoxy ❑ Straight Edge Ruler ❑ Thin and Thick C/A (Cyanoacrylate) ❑ Pencil ❑ Formula 560 Canopy Glue ❑ Airplane Stand ❑ C/A Debonder ❑ T-Pins ❑ Silicon Sealant ❑ Builder's Triangle ❑...
Page 5: Kit Contents
Kit contents Before you begin assembly, group the parts as we list them below. This will ensure that you have all of the parts before you begin assembly and it will also help you become familiar with each part. IF YOU FINd ANY PARTS MISSING OR dAMAGEd, PLEASE CONTACT US dIRECTLY , USING THE CUSTOMER SERVICE INFORMATION ON PAGE 2. airfraMe asseMBLies ❑...
Page 6 rudder controL sYsteM asseMBLY ❑ (1) Stranded Pull-Pull Cable ❑ (2) Threaded Control Horns ❑ (2) Clevises ❑ (2) Adjustable Control Horns ❑ (2) Couplers with Z-Bends ❑ (2) Threaded Couplers ❑ (4) Flanged Crimp Collets ❑ (3) M2 x 50mm Machine Screws ❑...
Page 7: Wing Assembly
WinG asseMBLY You'LL need tHe foLLoWinG parts froM tHe Kit: ❑ (1) Right Wing Panel with Aileron ❑ (8) C/A-Style Hinges ❑ (1) Left Wing Panel with Aileron You'LL need tHe foLLoWinG tooLs and suppLies: ❑ Thin C/A ❑ 1/16" (1.6mm) Drill Bit ❑...
Page 8 ❑ Remove the T-Pins and push the aileron up against the trailing edge. There should be no more than a 1/32" (.7mm) wide hinge gap and the tip of the aileron counter-balance should be even with the tip of the wing. ❑...
Page 9: Mounting The Wing
❑ Install the aileron servo into the mounting hole, making sure to drill 1/16" (1.6mm) diameter pilot holes for the mounting screws, then repeat the previous procedures to install the aileron servo into the second wing panel. IMPORTANT The servo output shaft should be toward the trailing edge of the wing.
Page 10: Stabilizer Installation
step 2: MountinG tHe WinG ❑ Cut away and remove the covering material from over the top and bottom of the two predrilled wing-screw holes in the trailing edge of the wing. The wing screw holes are located 2-5/8" (67mm) out from the center wing joint and 2-5/8"...
Page 11 ❑ Cut away the covering material from over the stabilizer mounting slot in each side of the fuselage. ❑ Slide the stabilizer into the mounting slot and center it by carefully measuring out from each side of the fuselage to each end of the stabilizer (at the trailing edge only for now).
Page 12 STep 2: InSTAllInG The STABIlIzeR ❑ Once you're satisfied with the alignment, draw a line on each side of the stabilizer where it meets the fuselage. Do this on both the top and the bottom. WARNING When cutting through the covering to remove it in the next procedure, cut with only enough pressure to cut through only the covering itself.
Page 13: Tail Wheel Installation
taiL WHeeL instaLLation You'LL need tHe foLLoWinG parts froM tHe Kit: ❑ (1) Rudder ❑ (1) Wheel Collar with Grub Screw ❑ (1) Tail Wheel Bracket ❑ (5) C/A-Style Hinges ❑ (1) Tail Wheel Wire with Tail Wheel and Wheel Collar ❑...
Page 14: Landing Gear Installation
❑ When satisfied with the fit and alignment, remove the tail wheel wire and use 220 grit sandpaper to roughen only the gluing surfaces of the wire. ❑ Glue the tail wheel wire into place, using a generous amount of 5 minute epoxy. Remove any excess epoxy, using a paper towel and rubbing alcohol, and allow the epoxy to set up before proceeding.
Page 15 step 1: instaLLinG tHe LandinG Gear BracKets ❑ Cut away the covering material from over the landing gear brackets mounting plate in the bottom of the fuselage. ❑ Install the two landing gear brackets, using six M4 x 20mm socket-cap screws and six M4 flat washers.
Page 16: Engine Installation
enGine instaLLation You'LL need tHe foLLoWinG parts froM tHe Kit: ❑ (2) Adjustable Engine Mounting Beams ❑ (8) M5 Flat Washers ❑ (4) M5 x 25mm Socket-Cap Screws ❑ (4) M5 Lock Nuts ❑ (4) M5 x 30mm Socket-Cap Screws ❑...
Page 17: Throttle Control System Installation
tHrottLe controL sYsteM instaLLation You'LL need tHe foLLoWinG parts froM tHe Kit: ❑ (1) 14" (356mm) Pushrod Wire with Z-Bend ❑ (1) Balsa Support Stick (Short) ❑ (1) Adjustable Pushrod Connector Assembly with Grub Screw ❑ (1) Hex Wrench ❑ (1) Plywood Servo Tray (Throttle) You'LL need tHe foLLoWinG tooLs and suppLies: ❑...
Page 18: Fuel Tank Assembly And Installation
step 3: instaLLinG tHe adJustaBLe pusHrod connector ❑ Cut away all but one arm from a "4-point" servo horn. ❑ Enlarge the hole in the servo arm that is 9/16" (14mm) out from the center of the servo horn, using a 5/64" (2mm) diameter drill bit. ❑...
Page 19 step 1: asseMBLinG tHe ruBBer stopper IMPORTANT Discard one of the longer aluminum tubes. It will not be used for our style of fuel tank setup. ❑ Push the two aluminum tubes through the rubber stopper, then slide the large diameter metal plate over the tubes at the front of the rubber stopper and slide the small diameter metal plate over the tubes at the rear of the rubber stopper.
Page 20: Elevator Control System Installation
❑ Wrap the fuel tank in one layer of 1/4" (6mm) thick foam rubber, using strips of masking tape to hold the foam rubber in place. ❑ Feed the ends of the fuel tubing through the predrilled hole in the firewall and slide the fuel tank into position, making sure that the fuel tank is pushed against the back of the firewall.
Page 21 ❑ Test-fit the servo tray into the fuselage, making sure that the servo tray fits down against the fuselage side doublers. The notches in the servo tray should fit in the notches in the fuselage side doublers. ❑ When satisfied with the fit, epoxy the servo tray into place, then glue one long balsa support stick to the top of each side of the servo tray and to the fuselage sides.
Page 22 ❑ Thread one adjustable control horn onto one threaded control horn, making sure that the top of the adjustable control horn is flush with the end of the threaded control horn. ❑ Position and mark the mounting hole locations for one control horn on the bottom of one elevator half.
Page 23 ❑ Carefully slide the split elevator pushrod assembly into the fuselage and guide the two threaded pushrod wires out through the elevator pushrod exit slots. ❑ Center the elevator servo, then install the servo horn onto the servo, making sure that the servo horn is centered and points toward the center of the fuselage.
Page 24: Rudder Control System Installation
rudder controL sYsteM instaLLation You'LL need tHe foLLoWinG parts froM tHe Kit: ❑ (1) Stranded Pull-Pull Cable ❑ (3) M2 x 50mm Machine Screws ❑ (2) Threaded Control Horns ❑ (3) M2 Flat Washers ❑ (2) Clevises ❑ (3) M2 Hex Nuts ❑...
Page 25 ❑ Position and mark the mounting hole locations for one control horn on one side of the rudder. When aligned properly, the centerline of the control horn should be 7/8" (22mm) above the bottom of the rudder (measured at the hinge line) and the clevis attachment hole should be lined up over the hinge line.
Page 26 ❑ Thread one clevis onto each of the two threaded couplers. ❑ Feed the plain end of each of the two lengths of cable through the rudder cable exit slots in the sides of the fuselage and into the servo compartment. ❑...
Page 27: Aileron Control System Installation
aiLeron controL sYsteM instaLLation You'LL need tHe foLLoWinG parts froM tHe Kit: ❑ (2) 8" (203mm)Threaded Pushrod Wires ❑ (2) Clevises ❑ (2) Threaded Control Horns ❑ (2) Snap-Keepers ❑ (2) Control Horn Backplates ❑ (6) M2 x 50mm Machine Screws ❑...
Page 28 ❑ Cut away all but one arm from a "4-point" servo horn. ❑ Enlarge the hole that is 3/4" (19mm) out from the center of the servo horn, using a 5/64" (2mm) diameter drill bit. ❑ Use a couple of pieces of masking tape, taped between the aileron and the wing panel, to hold the aileron centered. ❑...
Page 29: Cowling Installation
coWLinG instaLLation You'LL need tHe foLLoWinG parts froM tHe Kit: ❑ (1) Cowling ❑ (9) M2 x 10mm Flange-Head Wood Screws You'LL need tHe foLLoWinG tooLs and suppLies: ❑ Thin C/A ❑ Pencil ❑ # 1 Phillips Head Screwdriver ❑ Airplane Stand ❑...
Page 30: Canopy Installation
❑ Remove the spinner backplate and the cowling, then install the muffler assembly onto your engine. ❑ Cut away the bottom rear portion of the cowling for hot air to escape. To achieve adequate cooling, the total area of the air-exit slots should be approximately 30% larger than the total area of the air-intake holes.
Page 31: Final Assembly
❑ Secure the cockpit deck to the cockpit frame, using four M2 x 8mm flange-head wood screws. step 2: instaLLinG tHe canopY ❑ If you've purchased a pilot figure for your airplane, carefully paint and install it now before installing the canopy. ❑...
Page 32: C/G And Balancing
IMPORTANT In most cases the receiver and battery will need to be mounted as far forward as possible to balance the airplane. We don't suggest permanently installing the receiver and battery until you have balanced the airplane. How the airplane initially balances will determine where you need to mount them.
Page 33: Aircraft Setup Information
aircraft setup inforMation controL tHroWs We recommend initially setting up the airplane using the Test Flying control throws. These control throws are suggested for initial test flying because they will allow the airplane to fly smoother and make it easier to control. For sport flying and aerobatics, increase the control throws to the Sport Flying settings.
Page 34: Preflight Check And Safety
Guarantee Sportsman Aviation guarantees this kit to be free from defects in both material and workmanship at the date of purchase. This does not cover any component parts damaged by use, misuse or modification. in no case shall sportsman aviation's liability exceed the original cost of the purchased kit.
Page 35: Product Evaluation Sheet
Your privacy is important to us. 7) Was any of the assembly difficult for you? If yes, please explain. 1) Kit: sportsman aviation Giant scale corby starlet arf # 127533 ❑ Yes ❑ No...
Page 36: Global Services
_______________________________ _______________________________ post office will not deliver _______________________________ without proper postage (Return Address Here) Global Hobby Distributors attn: Global services 18480 Bandilier Circle Fountain Valley CA 92728-8610 fold along dotted line Page ...

Sportsman Aviation Giant Scale Corby Starlet Assembly Instructions Manual

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