Hobbico BrightStar 40 AWARF User Manual

• Learn to fly low-wings with AWARFease!

• Quick to build...flight-ready in just 16-20 hours

• Stable at low speeds—acrobatic at full throttle

Features like this easy-access
engine positioning will make
BrightStar maintenance fast
and simple.

You'll quickly make a successful step up to flying low-wings with your BrightStar 40 AWARE Its

90% prebuilt construction gets you out of the workshop and onto the flight line in only a matter
of hours. Then you can begin exploring the exciting acrobatic possibilities in the BrightStar's

low-mounted wing...without leaving behind the reasssuring durability and low-speed stability

of your basic trainer.

Easy as 1,2,3

Entire

Contents © Copyright

1996

HCAZ3077

V

1.0

Y

ou'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 modelers,
Hobbico's BrightStar offers nearly all the excitement of
piloting a real airplane...and develops skills that will take you
anywhere you want in your new hobby.

Take a moment now to match the box contents with the

items listed here. Following the BrightStar assembly
instructions will be quite easy if you identify and organize
the parts before you begin.

Engine Mounting Parts

Part # Quantity

43 6-32 x 3/4" machine screw.................4

44 #6 washers.......................................... 4

50 Wire pushrods....................................2

57 Pushrod guide tubes...........................2

59 #6 x 3/4" sheet metal screw................4

Tail Assembly

Please take your time and read through the instruction
manual before starting to build your new airplane. If
you have any questions, please feel free to give us a call
at [phone]. We hope you enjoy building and flying
the BrightStar 40.

Wing Assembly

Part# Quantity

1 Right

wing

with

aileron.............................

1

2 Left

wing

with

aileron...............................1

7 Plywood wing joiners................................3

19

Wing

center tape

.......................................1

21

Aileron

servo tray

......................................1

23 Aileron control horns................................2

24

Threaded

aileron

pushrods

......................2

25 Clevises......................................................2

28

Clear

clevis

retaining

tube........................

1

Part # Quantity

4 Horizontal stab and elevator.........1

5 Vertical fin and rudder...................1

25 Clevises ...........................................2

26 Control horns .................................2

28 Clear clevis retaining tube.............1

36 Dowel pushrods .............................2

46 2x15mm machine screws..............4

60 Dorsal fin ........................................1

61 Dorsal fin covering.........................1

2

Landing Gear

Part# Quantity

10 Main landing gear strut .............2

11

Nose gear

strut

...........................1

22 Wheel Pant

.................................3

27 Plastic steering

arm

...................1

29 Landing gear strap (Nylon) .......4

31 Wheel ..........................................3

32 Wheel collar / 3x5mm screw.....7

47 2.5xl0mm sheet metal screw....4

58 Pushrod connector ....................2

62 Landing gear strap (Metal)........3

* Sketches shown are not

actual size or to scale.

Inch Scale

Fuselage & Parts

Part # Quantity

3 Fuselage .................................1

8 Wing mounting dowel...........2

20 Servo tray ...............................1

40 Stabilizer mounting base......l

51 Spinner...................................1

52 Servo tray support.................1

Fuel Tank & Parts

Part # Quantity

12 Fuel tank ..............................................1

13

Rubber tank

stopper

...........................1

14

Fuel pick-up weight

(clunk)

...............1

15 Plastic stopper disk

(one large and

one

small)

...................2

16 Aluminum fuel tubing

(one short and two long)

....................3

17

3xl8mm

sheet metal screw

................1

18

Silicone fuel

line..................................1

33 Foam tank collar..................................1

3

Glues

Choose a high quality 6-minute and 30-minute epoxy, such
as Great Planes* Pro- Epoxy, which has been formulated
especially for R/C model building. Pro Epoxies offer a strong
bond and a variety of curing times suited for every step of
assembly. You'll also need a 1 oz. bottle of thin and a 1 oz.
bottle of medium CA (Cyanoacrylate), plus rubbing alcohol
for easy epoxy cleanup.

Hardware

Tools and accessories required for assembly
include a hobby knife, small and large Phillips
screwdrivers, needle nose pliers, drill with

1/16", 11/64", 5/64", 3/32", 5/32" and 3/16"
bits, ruler, #64 rubber bands, one foot of
medium fuel tubing and petroleum jelly

Model Engine

Power your BrightStar with any high-quality,
.40 - .46 size model engine. The O.S. .40 LA is a
fine engine for this plane. 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 control your BrightStar's "flight path," you'll need a 1991
legal 4-channel aircraft radio system with four standard
servos. Many 4-channel radios include just three. You may
need to purchase the fourth separately. Hobbico Command
servos are available singularly and will work great for this
plane. The servos, battery pack and radio receiver will be
mounted onboard your model and need to be cushioned
from jolts and vibration. Half-inch thick foam rubber sheets

(HCAQ1050) are available for this purpose.

Getting Ready for Flight

Your Hobbico BrightStar can be ready for takeoff in as little as 16-20 hours.
Your hobby dealer or flying instructor (see next page) can help you decide what

accessories you'll need for flight. Most are one-time-only purchases - like a

glow plug igniter (see glossary), fuel pump, and "chicken stick" or electric

starter. You will also need to obtain model glow fuel. Use glow fuel with a

10-15% nitro content to keep your engine performing at its peak.

General Items Required

Mixing Sticks (GPMR8055)
Epoxy Mixing Cups
Clothespins
Foam Rubber (HCAQ1050)
String

Felt-tip Pen
Easy-Touch" Bar Sander

(GPMR6170)

150-grit sandpaper

(GPMR6183)

Adjustable Wrench
Masking Tape
Medium 3/32" Fuel Tubing

(GPMQ4131)

Paper Towels

T-pins
Wire Cutter
Epoxy Brush
Steel File
Wax Paper

4

If you're a beginner, the best way
to begin flying your BrightStar is
with an experienced R/C pilot or
flying instructor at your side. You'll
learn faster 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 should also join the
Academy of Model Aeronautics

(AMA), a 165,000 member-strong

national organization with more
than 2,300 chartered clubs across
the country. Through any one of
them, instructor training programs
are available. Contact the AMA at
the address or phone number
below.

Academy of Model Aeronautics

5151 East Memorial Drive
Muncie, IN 47302-9252
[phone]

Fax[phone]

Before you fly:

1. Make sure that no other fliers are using your
radio frequency.

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

3. Double check all control surfaces, making sure they arc
secure and move in the proper direction.

4. Make sure that the transmitter & receiver batteries are
fully charged.

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. Model fuel will evaporate, so
make sure that you always store it with the
cap secure.

When starting and running your engine:

1. Always wear safety glasses.

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

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

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

5. 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.

6. 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 a defect 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 BrightStar 40 must be returned directly to Hobby Services for warranty
work The address is Hobby Services, Attn Service Department, 1610 Interstate
Drive, Champaign, IL 61821-1067 Phone [phone], or for product
information and technical support please contact us at [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

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

5

Special Note:

You should charge your radio system before starting to
build. Following the manufacturer's directions, connect
your transmitter and receiver batteries to the system's
charger. This way the radio will be ready when it is time
to install and test the components.

Prepare the wing joiners

both sides of one of the wing joiners. Sandwich this
coated joiner between the remaining two. Make sure
that the centerlines drawn in step 1 are visable on both
sides of the assembly. Quickly proceed through the
following steps (3 and 4) before the glue cures.

Remove the excess epoxy

D 1. Locate the three 1/8" (3mm) die-cut plywood
wing joiners. Arrange the "V'-shaped joiners in the

same orientation as they will be glued together. Sand
off any bumps from the edges. Draw a centerline on
two of the joiners as shown.

D 3. Excess epoxy will squeeze 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.

Glue the wing joiners

Note: Please read steps 2 through 4 before mixing epoxy.

D 2. Mix approximately 1/4 oz. (7.5ml) of 30-minute
epoxy using a mixing stick and a cup. Using a mixing
stick or epoxy brush, apply an even coat of epoxy on

Clamp the wing joiner

D 4. Use clothespins to clamp the wing Joiners firmly

together. If any more epoxy squeezes out, remove it
using a paper towel. Make sure the joiners are evenly
lined up with each other. Set the joiner assembly aside
until the epoxy has fully cured.

6

Even the edges

D 5. Using a bar sander or similar tool, sand the wing
roots so they will fit together with no gaps. Do not sand
too much or the dihedral angle could change.

Mark the wing servo cavity

D 6. Mark the aileron servo location on both wing

panels using a felt-tip pen. Using a hobby knife, cut an
opening into both panels following the lines you

just drew.

wing joiner will not fit in the cavity, lightly sand any

excess epoxy or uneven surfaces from the joiner edges,
sides and ends.

Caution: A snug fit is desirable between the joiner and
the wing cavity. Do not sand excessively.

Viewing the wing dihedral

D 8. Pay close attention to the orientation of the wing

joiner in relation to the wing panel, creating the

dihedral angle as shown. Test fit the wing panels
together. They should fit flush against each other

without gaps.

Note!

When performing the following steps, be sure
to use a sufficient amount of epoxy to form a complete
and solid bond between the plywood wing joiner and
the two wing halves. This is the most important glue

joint in the entire airplane.

Please read through the following three steps before
mixing any epoxy. You must complete these steps
within 20 minutes from the time you mix the epoxy.

Glue the joiner

Test fit the wing joiner

D 7. Test fit the wing joiner in both wing panels by
sliding the joiner into the joiner cavity in the wing. The

joiner should slide in snugly up to the centerline. If the

D 9. Mix 3/4 oz. (22ml) of 30-minute epoxy. Use a
mixing stick or epoxy brush to apply epoxy to all four
sides of the joiner cavity. Insert the joiner into the
cavity up to the centerline marked on the joiner plate.
Be sure you are installing the joiner correctly. Quickly
proceed to the next step.

7

Apply epoxy to the wing root rib Test fit the aileron servo

D 10. Apply epoxy inside the joiner cavity of the
remaining wing panel. Next, coat the wing root ribs on

both panels. Quickly proceed to the next step.

Join the wing halves

D 11. Assemble the two wing halves with the tightest
seam possible. No gaps should be showing between
the two wing halves. Clean any excess epoxy from the
outside of the wing using a paper towel dampened
with rubbing alcohol. Use several strips of masking
tape on both sides to hold the wing halves tightly
together. Let the epoxy fully cure before continuing.

D 13. Test fit the aileron servo into the servo tray and
the hole in the top of the wing. Enlarge either hole, if
needed, with a hobby knife or a fine-toothed file until a
proper fit is achieved. The plywood tray should not
actually contact the the sides of the servo. Leave a

1/64" gap all the way around. Remove the servo. The

servo should not touch any of the wing surface.

Install the servo tray

Trim the covering

D 12. Hold the plywood aileron servo tray over the
hole in the top of the wing. Trace the outside of the tray
with a felt-tip pen and then remove the tray from the
wing. Carefully remove the covering within the lines

using a new #11 blade in a hobby knife, being careful
not to cut into the balsa wing sheeting.

D 14. Mix l/8oz. (3.5ml) of 6-minute epoxy to glue the
servo tray to the top side of the wing. Attach the servo
tray to the top of the wing. After the epoxy has cured,
cut a small notch in the servo tray to allow the servo
lead to pass through.

Apply the wing center tape

D 15. Starting at the front of the aileron servo tray,
apply the 1/2" (12.5mm) white wing center tape

8

completely around the wing over the joint. A small
amount of pressure should be applied to make a
smooth seam.

Check the aileron hinge

D 16. Gently tug on each of the ailerons at each hinge
location. If any of the hinges are loose, reglue them as

described here. First, flex the surface all the way one
direction (DO NOT REMOVE THE AILERON).

Install the aileron control horns

D 17. Thread the aileron control horns onto the torque
rods until there is 3/4" (19mm) of torque rod between
the wing and control horns.

Assemble the pushrods

Apply 5 drops of thin CA onto each hinge.

NOTE: Do not use CA accelerator as the CA must

"wick" into the slot. Use a paper towel to absorb any
excess glue. Wait a few minutes for the glue to cure,
then flex the surface the other direction and glue the

other side of the hinges in the same manner. Finally,
flex the surface back and forth several times to free up
the aileron.

D 18. Locate two plastic clevises and two 8 (203mm)
aileron pushrods. Thread the clevises onto the
threaded end of the pushrods until the rod protrudes

between the clevis forks 1/16".

Install the pushrods

D 19. Attach the pushrods to the aileron control horns.
Press the forks of the clevis together until they snap
into place.

9