Hobbico Avistar Assembly Instructions Manual

ASSEMBLY INSTRUCTIONS

90-Day Limited Warranty

If you, as the original owner of this model, discover defects in pans or workmanship wilhin 90 days of purchase, Hobbico will repair or replace it - at the option
of our authorized U.S. repair facility, Hobby Services - without charge. Our liability does not include cost of shipping to us. However, Hobby Services will pay
shipping expenses lo return your model to you. You must provide proof of purchase, such as your original purchase invoice or receipt, for your model's
warranty to be honored. This warranty does not apply to damage or defects caused by misuse or improper assembly, service or shipment. Modifications,
alterations or repair by anyone other than Hobby Services void this warranty. We are sorry, but we cannot be responsible for crash damage and/or resulting
loss of kits. engines, accessories, etc.

Repair Service

Your Avistar must be returned directly to Hobby Services for warranty work. The address is: Hobby Services. Attn: Service Department. 1610 Interstate Drive,
Champaign, II. 61822 Phone: [phone]. Please follow the instructions below when returning your model. This will help our experienced technicians to
repair and return it as quickly as possible.

1. ALWAYS return your entire system, including airplane and radio.

2. Disconnect the receiver battery switch harness and make sure that the transmitter is turned off Disconnect all batteries and drain all fuel.

3. Include a list of all items returned and a THOROUGH, written explanation of the problem and service needed. If you expect the repair to be covered under
warranty, also include your proof of purchase.

•I.

Include your

full

return

address

and a phone number where

you

can

be

reached during

the

day.

If your model is past the 90-day warranty period or is excluded from warranty coverage, you can still receive repair service through Hobby Services at a
nominal cost. Repair charges and postage may be prepaid or billed COD. Additional postage charges will be applied for non-warraiuy returns All repairs
shipped outside the United States must be prepaid in U.S. funds only All pictures, descriptions and specifications found in this instruction manual and on
the product package arc subject to change without notice. Hobbico maintains no responsibility for inadvertent errors.

Entire contents © Copyright 1999

HCAZ3037 for HCAA2016 V 1.0

AVISTAR 40 ARF IMPORTANT BUILDING NOTES?

Please make notes of the following points in your instruction manual before beginning assembly.

6-32 X 3/4"

This kit contains an adjustable engine mount. This will allow you mount almost any engine
quickly and easily. To use this mount, please replace the following steps in the manual with

these:

Engine Mount

Machine Screws

1. On page 16, at step 31, drill a hole in the firewall so it is 9/16" in from the right side and
3/8" up from the bottom as shown in the sketch at right.

3/8"

2. On page 17, before step 35, install the engine mount halves by fitting them together and
attaching them to the firewall using four 6-32 x 3/4" machine screws with washers. Do

not tighten completely until later.

9/16"

3. On page 17, at step 36, install the nose gear strut through the steering arm, followed by a 4mm

collar. Next, slide the strut through the lower lug on the engine mount and install a second collar
(see sketch at right). Tighten the collars using 3 x 5mm machine screws.

Nose gear

strut

4. On page 17, at step 37, rotate the steering arm so it is 1/2" away from the firewall with the wheel

pointing straight ahead.

4mm

Collars

5. On page 18, after step 46, once the engine in properly positioned, tighten the engine mount to

the firewall.

6. On page 19, step 47, drill four 7/64" holes at the marks. Do not drill 1/8" holes.

7. On page 19, step 50 will tell you to mount the engine using four 3 x 25mm machine screws with washers and nuts. This hard

ware has been replaced with four #6 x 3/4" sheet metal screws. Simply screw these into the mount to hold the engine in piace.

AV12ADD2

You're about to build in just days what took aviation pioneers years—a powered machine that flies.
Specially created for you and other first-time radio control acrobatic pilots, Hobbico's Avistar 40 offers
nearly all the excitement of piloting a real airplane...and develops skills that will take you anywhere you
want in your new hobby.

Know Your Model's Parts

Take a moment now to match the box contents with the items listed below. Following the Avistar 40's
assembly instructions will be quite easy if you identify and organize the parts before you begin.

1. RUDDER/FIN (C)

2. STABILIZER/ELEVATOR

(C)

3. LEFT WING PANEL

(A)

4. RIGHT WING PANEL

(A)

5. FUEL TANK (B)

6. SPINNER

(B)

7. FUSELAGE

(B)

8. SERVO TRAY

(B)

9. WHEELS (D)

10.

MAIN LANDING GEAR

(D)

11.

METAL HARDWARE (B)

12.

NYLON HARDWARE

(B)

13.

PUSHRODS (B)

14. WING

DOWELS

(B)

15.

DIHEDRAL BRACES

(A)

16.

HARDWARE (B)

17. NOSE

GEAR

(D)

18. ONE-PIECE ALUMINUM ENGINE MOUNT (B)

19.

BATTERY / RECEIVER TRAY

(B)

Replacement Parts Available

HCAA3030.....Wing Kit (A)

HCAA3031..... Fuselage Kit (B)

HCAA3032.....FinSet(C)

HCAA3033.....Landing Gear Set (D)

() Letter indicates items included in each replacement set.

2

Other Items You'll Need

Glues

Choose any 6-minute epoxy, such as Great Planes®
Pro'" Epoxy, which has been formulated especially
for R/C model building. Epoxies offer a strong

bond and a variety of curing times suited for every

step of assembly. You'll also need an instant-setting
CA (cyanoacrylate), a thicker CA+, and a 30-minute
epoxy, plus rubbing alcohol and paper towels for
easy epoxy cleanup.

Hardware

Tools and accessories required for assembly:

Hobby knife Needle nose pliers
#11 knife blades Large Phillips screwdriver
#64 Rubber bands Small Phillips screwdriver
Ruler 3 ft of 3/32" fuel tubing
Drill with drill bits: 1/16", 3/32", and 3/16"

Model Engine

Power your Avistar with any high-quality, .40-size
model engine. The O.S.® .40 LA and SuperTigre®
GS-40 are just a few examples. Look for features
such as easy break-in, easy starting, efficient
carburetion and low maintenance. Check the
manufacturer's recommendations for propellers to
use with your engine.

Radio Equipment

To let you send the commands that control your
Avistar 40's "flight path," you'll need a 4-channel
aircraft radio system with four standard servos.
Many 4-channel radios include just three servos.
You may need to purchase the fourth separately.
The servos and radio receiver will be mounted on­board your model and need to be cushioned from
jolts and vibration. One-half inch thick foam
rubber sheets are available for this purpose.

Getting Ready for Flight

Your Hobbico Avistar 40 trainer is ready for takeoff
in as little as 15-20 hours. Your hobby dealer or
flying instructor can help you decide what
accessories you'll need for flight. Most are one-time
only purchases—and your instructor will probably
allow you to use his field box until you can outfit
your own with a glow plug starter, fuel bulb or
pump, and "chicken stick" or electric starter. You

will need to provide your own fuel. Use glow fuel
with a 10-15% nitro blend to keep your engine
performing at its peak...and your Avistar 40 will
have the power to make you an accomplished pilot!

Other General Items Required:

Masking Tape

Epoxy Brushes
T-Pins
Clothes pins
Sandpaper
Foam Rubber
Mixing Sticks

Felt-Tip Marker
String
Paper Towels
Standard Screwdriver
Thread Locking Compound

Epoxy Mixing Cups Wing Seating Tape

Find A Flying Instructor

The best way to begin flying your Avistar 40 is with
an experienced R/C pilot or flying instructor at
your side. You'll learn faster, relax those in-flight
jitters and avoid risking your model before you're
truly ready to solo.

Where do you find an instructor? Ask at your local
hobby shop. They'll have information about flying
clubs in your area whose membership includes
qualified instructors. You can also join the

Academy of Model Aeronautics (AMA), a 165,000

member-strong national organization with more

than 2,500 chartered clubs across the country.
Through any one of them, instructor training
programs and insured newcomer training are
available. Contact the AMA at the address or phone
number below:

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302

Toll Free: [phone]

Fax: [phone]

Web Site: http://www.modelaircraft.org

3

Please follow these safety precautions:

Before you fly

1. Make sure that no other flyers are using your

radio frequency.

2. Your radio transmitter must be the FIRST thing
you turn ON, and the LAST thing you turn OFF.

Fuel storage and care

1. Do not smoke near your engine or fuel.

2. Store all engine fuel in a safe, cool, dry place,
away from children and pets.

3. Always wear safety glasses.

4. Make certain that your glow plug clip is securely
attached to the glow plug—and cannot pop off,
possibly falling into the spinning propeller.

5. Use a "chicken stick" or electric starter to start
the engine— NOT your fingers.

6. Make sure that the wires from your starter and
glow plug clip cannot become tangled with the
spinning propeller.

7. Do not stand at the side of the propeller when
you start or run the engine. Even at idle speed,
the spinning propeller will be nearly invisible.

8. If any engine adjustments are necessary,
approach the engine only from behind the
spinning propeller.

90-Day Limited Warranty

If you, as the original owner of this model, discover
defects in parts or workmanship within 90 days of
purchase, Hobbico will repair or replace it—at the
option of our authorized U.S. repair facility, Hobby
Services—without charge. Our liability does not
include cost of shipping to us. However, Hobby
Services will pay shipping expenses to return your
model to you.

You must provide proof of purchase, such as your
original purchase invoice or receipt, for your
model's warranty to be honored.

This warranty does not apply to damage or defects
caused by misuse or improper assembly, service or
shipment. Modifications, alterations or repair by
anyone other than Hobby Services voids this
warranty. We are sorry, but we cannot be
responsible for crash damage and/or resulting loss
of kits, engines, accessories, etc.

Repair Service
Your Avistar 40 must be returned directly to Hobby
Services for warranty work. The address is:

Hobby Services,

Attn: Service Department

1610 Interstate Drive, Champaign, IL 61822

Phone: [phone]

Please follow the instructions when returning your
model. This will help our experienced technicians
to repair and return it as quickly as possible.

1. ALWAYS return your entire system, including
airplane and radio.

2. Disconnect the receiver battery switch harness
and make sure that the transmitter is turned off.
Disconnect all batteries and drain all fuel.

3. Include a list of all items returned and a
THOROUGH, written explanation of the
problem and service needed. If you expect the
repair to be covered under warranty, also
include your proof of purchase.

4. Include your full return address and a phone
number where you can be reached during the day.

If your model is past the 90-day warranty period or
is excluded from warranty coverage, you can still
receive repair service through Hobby Services at a
nominal cost. Repair charges and postage may be

prepaid or billed COD. Additional postage charges
will be applied for non-warranty returns. All
repairs shipped outside the United States must be
prepaid in U.S. funds only.

All pictures, descriptions and specifications
found in this instruction manual and on the
product package are subject to change without
notice. Hobbico maintains no responsibility for
inadvertent errors.

4

Q Find the two 1/8" (3mm) die-cut plywood wing
joiners. Draw a center line on both sides of the

plywood wing joiners and balsa aileron servo tray
mounting blocks. Use one plywood joiner as a
template to mark the wing dihedral angle on both
of the balsa 5/16" x5/16" x 1-1/2" (8mm x 8mm x
38mm) aileron servo tray mounting blocks. Put
these mounting blocks aside for use later.

Orientation of the wing joiners

Q Arrange the two "V-shaped plywood wing
joiners in the same orientation as they will be
glued together.

Gluing the wing joiner

Q Mix approximately l/4oz. (7.5ml) of30-minute
epoxy. Using a mixing stick or epoxy brush, apply
an even coat of epoxy on one side of a wing joiner.
Stack the other joiner on top of the epoxy.

Clamping the wing joiner

l-l Use three clothes pins to clamp the wing joiners

together firmly. The excess epoxy must be removed

before it cures as described in the next step.

Removing the excess epoxy

l-l Excess epoxy will be squeezed out of the seams
between the joiners and must be removed before
the epoxy is allowed to cure. Use a paper towel and
rubbing alcohol to remove the excess epoxy.
Be careful not to disturb the alignment of the

joiner pieces.

Test fit the wing joiner

After the epoxy has cured and the clothes pins
have been removed, test fit the wing joiner in both
wings by sliding the joiner into the joiner cavity in
the wing. The joiner should slide in with a little
resistance up to the centerline drawn on the both
sides of the joiner.

5

Sanding the joiner

Cl If the wing joiner will not Fit in the cavity, lightly

sand the excess epoxy and uneven surface joints
from the joiner edges and sides. Caution: A snug fit
is desirable between the joiner and the wing cavity.
Do not sand excessively.

Viewing the wing dihedral

Cl Pay close attention to the orientation of the wing

joiner in relation to the dihedral of the wings.

Marking the wing cavity

1-1 Lay the wing halves on the work surface with the

flat side facing up. Remove the precut balsa from the
root rib. Using the measurements in the sketch, trim
away the balsa sheeting from the bottom of the wing
to allow for the installation of the aileron servo.

Gluing the joiner in the wing

1-1 Mix l/4oz. (7.5ml) of 30-minute epoxy to glue

the joiner into one wing half. Use a mixing stick or

epoxy brush to apply epoxy to all four sides of the
joiner cavity wall. Insert the joiner into the cavity

up to the centerline marked on the joiner plate. Be

sure you are installing the joiner in the correct

orientation to the wing. It should angle upwards

when installed correctly. Clean the excess epoxy

from the wing root rib. You must be sure all the

excess glue is removed from the wing root or the

wings will not fit together correctly. Allow enough

time for the epoxy to fully cure before proceeding

to the next step.

Applying the epoxy

l-l Mix l/2oz. (14.5ml) of 30-minute epoxy and
apply to the wing root rib and inside the joiner
cavity of the second wing half.

Joining the wing halves

Q Assemble the two wing halves with the tightest
seam possible. No gaps should be showing between
the two wing halves. Clean the excess epoxy from
the outside of the wing using a paper towel and
rubbing alcohol. Tape the wing halves together with
masking tape. Set the wing aside to cure.

Cutting the mounting blocks

l-l Find the aileron servo tray and the two balsa
servo tray mounting blocks and position them
with the marked dihedral line up. Using a sharp

hobby knife, cut the angle out of the block. This

angle will be placed against the wing when the
servo tray is installed.

6

Assembling the servo tray

Q Apply thick CA+ to the flat side of the balsa servo
tray mounting block. Place the mounting block on
the aileron servo tray next to the servo
opening-not on the outer edge of the tray. Note the
positioning of the dihedral angle in relation to the
servo tray.

Q Test fit the aileron servo into the servo tray and
the hole cut in the bottom side of the wing. Enlarge
either hole, if needed, with a hobby knife or a fine­toothed file until a proper fit is achieved.

Removing the covering

Q Position the aileron servo tray so it is centered
over the opening made in the wing. Using a felt-tip
marker, trace the outside of the servo tray
mounting block onto the wing. Use a sharp hobby
knife to remove the covering for the mounting
blocks. Use care not to cut into the underlying
balsa of the wing, as this may weaken the wing.

Installing the servo tray

J Mix l/8oz. (3.5ml) of 6-minute epoxy to glue the
servo tray to the bottom side of the wing. Apply
equal amounts of epoxy to the mounting blocks on
both ends of the servo tray. Attach the servo tray on
the bottom of the wing with the servo wire harness
notch facing the trailing edge of the wing. The
mounting blocks should be attached to the wing
sheeting where the covering was removed and not
to the plastic wing covering. Allow the epoxy to
fully cure before proceeding to the next step.

Aileron installation

HINGES

TORQUE

ROD

l-l Test fit the ailerons on the wing with the hinges
installed. Check for free movement in both
directions. There should be no binding. Use a
toothpick to push 30-minute epoxy down the
torque-rod holes in each aileron. Fit the aileron in
place. There should Be virtually no gap when the
aileron is fully seated. If the aileron will not fully
seat, use a hobby knife to clean the hinge slots and
try it again. Glue in the hinges by wicking 4 drops
of thin CA into each side of the hinges.

7