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Wing Assembly: I like to start
on the wing since it is the biggest and the easiest part to finish. It
makes me feel as though I have accomplished a whole lot in a short time.
All RTF trainers use metal spars to align the wing halves and to ensure
a strong wing center-section. There is usually a smaller rear metal pin
to further align the wing halves. If the wing has a plastic center rib,
as the Hobbico NexSTAR does, the rear pin is omitted.
Slide the metal
spar into place and attach the second wing half. Each center wing rib is
coated to make it fuelproof. Sometimes this coating flows into the spar
and rear pin holes. Tolerances of the spar-to-rib hole are tight to
ensure a stiff wing. The smallest amount of coating inside the hole can
prevent the spar from sliding in.
If that happens, use a fine,
medium-size, round filea rat-tail fileto gently remove only the
coating. Never enlarge the hole itself.
Hobbico wing halves usually
screw in place, as on the Avistar 40 advanced trainer. Hangar 9 wings
are secured using clear tape. Either method is good for approximately
200 flights; after that, the constant flexing, sudden pullouts, and
"difficult" landings take their toll, and the wing spar begins to wear
its wing rib mounting holes, allowing the wing to get sloppy. Both
methods allow perfect wing alignment, so that is not a problem.
Use an
extra-sharp hobby knife to remove only the covering that overlaps the
wing center-section. Lightly block-sand the wing halves. Brush a thin
film of 30-minute epoxy onto one wing's center rib. Assemble the wings
as in the directions, hold them together with masking tape, make sure
the LEs and TEs are aligned, and allow to dry.
This RTF wing will never
loosen and will stay true throughout the most strenuous maneuvers. Hold
off on connecting the aileron control rods for now.

Click on photo to view large image with caption
Reinforcing the
Fuselage: Notice how nice the servos look in one of the photos, all in
place and with everything connected. It is good to have an installed
fuel tank as well, and the engine is comfortable nesting in its
preinstalled mount. It seems a shame to disturb all of that nice work,
but I am going to do just that.
Experience has shown that some problems
develop past the 100- to 200-flight mark that can be prevented at this
point. You may consider 200 flights too many to worry about, but it
represents only 10-20 weekends of five flights a day. That is less than
one season.
The servos are mounted on a thin plywood plate using small
screws, which sometimes loosen after many flights. It is a good idea to
center each servo's control armthe part to which the control rod
connectsand then remove the center screw and control arm and the four
servo-mounting screws. Remove the servos, but leave them connected to
the receiver.
Hobby shops sell 1/8 x 1/2 spruce rails that are roughly
36 inches long. Cut two rails approximately 1/4-inch shorter than the
inside width of the fuselage. Glue the two rails with thick cyanoacrylate onto the bottom side of the servo tray.
Move the servos
and wires out of the way, insert one rail through one of the two rear
servo holes, and rotate it widthwise. Apply the adhesive and hold in
place. It is best to position each rail slightly outside the plywood
tray's servo hole so that the servo fits back into place easily.
After
installing the large rails, cut two smaller rails for the throttle-servo
mount and install them. In the end, the bottom of your servo tray should
look like the one shown. Drill through the existing servo mounting holes
with a 1/16-inch-diameter drill bit, and then replace the servos and all
connections. Make sure the servos are centered and all control surfaces
are in their original positions. Do the same for the wing's aileron
servo because it gets the most stress.
All RTF aircraft feature bolt-on
tail feathers. Hangar 9 trainers mount the vertical fin to the
horizontal stabilizer using two bolts. Two additional bolts mount this
assembly onto the fuselage, as shown. Hobbico RTFs use two long threaded
rods mounted inside the vertical fin that pass through the stabilizer
and are bolted to the fuselage bottom, as is also shown.
Both systems
provide perfect alignment but wear in time. Eventually the wood around
the bolt holes distorts, enlarging the holes and allowing the stabilizer
to rotate in position.
The solution is to epoxy the stabilizer in place
using the stock mounting system for alignment. Install the fin and
stabilizer in place. You may find it easier to accomplish this using a
00 Phillips screwdriver to align the fuselage and stabilizer bolt holes
first. After everything is in place, draw a line with a fine-point
felt-tip marker onto the stabilizer's top and bottom where it meets the
fuselage sides.
Disassemble the stabilizer and fin, and cut away the
covering 1/16 inch inside the lines on the top and bottom of the
stabilizer. Use a sharp #11 blade, but be careful not to cut into the
wood. Apply 30-minute epoxy to the fuselage plates that mount the
stabilizer. Not much adhesive is needed since the only intention is to
reinforce the stock mounting system. Install the vertical fin and
stabilizer and let dry.
I have never experienced a loose vertical fin,
but you can epoxy it in place if you wish. Remember to remove any
covering from the fin's bottom as you did on the wing center-sections.
Connect the elevator and rudder control rods. Be sure to use the
silicone "keepers" to lock each clevis closed.
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