Hobbico Diabolo 40 User Manual
ALMOST READY-TO-FLY RADIO CONTROLLED MODEL AIRPLANE
• SUPERIOR QUALITY IN AN ALMOST-READY-TO-FLY MODEL
• SPECIAL COVERING PROCESS YIELDS A STRONG,
BRILLIANT, AND FUEL-PROOF FINISH
• 90% COMPLETE OUT OF THE BOX—NO SANDING, PAINTING, OR
FINISHING REQUIRED
• SMOOTH, STEADY FLIGHT CHARACTERISTICS, JUST LIKE
A REAL PLANE
• CAPABLE OF FULL 4-CHANNEL AEROBATICS
© ENTIRE CONTENTS COPYRIGHT 1989, HOBBICO, INC. V1 .0
IMPORTANT: BEFORE YOU BEGIN.
Congratulations on your choice of an ASAP kit BEFORE you begin assembly, carefully look through the box and
thoroughly read the instruction manual Also check the parts list against the items in the box to be sure you have
everything that is on the parts list Although we have taken great pains to simplify the building process, there are no
shortcuts to safety These instructions are your guide to safe and successful flying
Only after you are thoroughly familiar with the construction process should you proceed with assembly
REMEMBER! Under no circumstances will a dealer accept a kit back for return if assembly has
already begun.
If the Diabolo 40 is not quite what you expected, return it to your dealer in NEW and UNUSED condition
However, we think you will agree with us that the Diabolo 40 is one of the finest models of its type and will offer you
many hours of enjoyment
BEFORE ASSEMBLY
CONSTRUCTION HINTS:
(1) Trial fit each part before gluing Be certain that the parts fit properly
(2) Use PlastiZap or a thin type Cyanoacrylate glue for installing
the plastic parts Do not use too much as it may run and spoil the
appearance Do not get Cyanoacrylate on the foam parts of the Diabolo
Cyanoacrylate will destroy the foam
(3) It is best to use 30 minute epoxy where required This allows time to
position the parts before the epoxy cures
(4) Before assembly, place your radio system on charge
ADDITIONAL ITEMS
Most engines require a 1.5V glow plug starting battery a glow plug clip and a
quality brand fuel (consult the engine manufacturer's recommendations)
The following items are needed for completing the Diabolo 40 kit
Medium Fuel Tubing (12 ") (1)
40 45 Sized 2 Stroke (1)
or
60 70 Sized 4 Stroke (1)
4 Channel Radio System (1)
Pacer PlastiZap CA Glue (1)
Screw Locking Compound (Pacer Zap Lock) (1)
Goldberg #481 Foam Rubber (1)
30 Minute Epoxy (1)
Silicone Sealer (1)
Dubro 121 E Z Connects (Optional) (2)
Dubro 203 Kwik Switch Mount (Optional) (1)
TOOLS —
You will need the following tools to assemble the Diabolo 40 X Acto knife,
Phillips screwdriver (small and medium) needle nose pliers drill drill bits sand
paper and ruler
A quality brand engine will be needed We recommend the OS 40 FP or 40 SF
2 stroke engine A prop and fuel tubing will be required for the engine
A four channel radio control system with 4 servos is required for the Diabolo 40
The various components are pictured above
-2-
PARTS LIST
Before assembly match the parts in the
exploded view of the Diabolo with the
parts in the kit. Check off each part on
the parts list. If any parts are missing or
damaged return the kit to your hobby
dealer.
Check to make sure that all the listed
parts are included in your kit.
1 Fuselage
2 Right Wing
3 Left Wing
4 Wing Center Cover (Plastic)
5 Vertical Fin
6 Rudder
7 Horizontal Stabilizer (Stab.)
8 Cowl
9 Fuel Tank
10 Neoprene Ring
11 Plastic Disc (Small)
12 Plastic Disc (Large)
13 Silicone Tubing
14 Clunk
15 3x18mm Self Tapping Screw
16 Rubber Plug
17 Plastic Collar
Aileron Horn
Control Horns
Snap Clevis
Rod Clevis
Back Plates
18 Fuel Pipe
19 Mounting Plates (Angled)
Mounting Plates (Rectangle)
20 Clevis Retaining Tube
21 Push Rod Exits
22 Stab. Root Cover (Plastic)
23 Wheel
24 Main Gear
25 Wheel Pants
26 Cock Pit
27 Canopy
28 Main Wing Joiner
29 Rear Wing Joiner
30 Front Wing Joiner
31 Rubber Shock Absorber
32 Cowl Brace
33 Aileron Servo Tray Mount
34 Aileron Servo Tray
35 8mm Dowel Rod
36 Wing Bolt Mounting Block
37 Balsa Tank Support
38 Wing Mounting Brace
39 3x12mm Self Tapping Screw
Spinner
Spinner Back Plate
40 Engine Mount
41 Mounting Plates
42 Shrink Tubing
43 Control Rod (Short-Bent)
44 Aileron Control Rods (Short)
45 Throttle Control Rod (Long)
46 Throttle Tube
47 Wood Push Rods
48 Control Rod (Long)
49 Main Servo Tray
50 Stabilizer Supports
51 Plastic Disc
52 Cock Pit Mounts
53 Brass Sleeve
Brass Tube
54 Tail Wheel
55 Spring Steel Strip
56 Tail Gear
57 Tail Control Arm
58 Springs
59 Brass Arms
60 0-Ring
61 Collars
62 Wheel Collar
63 4x40mm Screw
64 4x30mm Screw
65 2x15mm Screws
66 3x8mm Self Tapping Screw
67 3x8mm Screw
68 3x12mm Self-Tapping Screw
69 3x5mm Screw
70 3.5x15mm Screw
3x12mm Screw
71 4x15mm Screw
72 4x20mm Screw
73
4mm
Nut
74
2mm
Nut
75
3mm
Nut
76 4mm Washer
77 3mm Washer
78 2mm Washer
79 Lock Washers
80 4mm Washer
81 4mm Nylon Nut
82 1/8" Plywood Wedge
-3-
WING ASSEMBLY
(A) Right Wing (Aileron Installed) ... 1
(B) Left Wing (Aileron Installed) .... 1
(C) Main
Wing
Joiner
.........
2
(D)
Rear
Wing
Joiner
........
1
(E)
Front
Wing
Joiner
.........
1
(F) Wing Center Cover (Plastic) .... 1
(G)
8mm
Dowel
Rods
.........
2
(H) Wing Bolt Mounting Block ..... 1
(3) Remove the foam covering from the aileron servo mounting area. Test fit the
main wing joiner and the rear wing joiner in the right and left wing sections. The
dihedral angle of the joiners should make the wing tips slightly higher than the
center.
(I)
Wing
Mounting
Brace
........
1
(J)
4x30mm
Bolts
........
.2
(K)
4mm
Washer
..........
.2
(L) 0-Ring . ............ .2
(M) Aileron Servo Tray ......... 1
(N) Aileron Servo Tray Mount ..... 1
(0)
Main
Servo Tray
..........
1
(1) Check each wing half for smooth aileron operation. It is a good ideal to exercise
(move back and forth) the ailerons to insure easy deflection. Sand the end if any
rubbing is noticed.
(4) Make sure that there is no gap between the wing halves. If there is, sand the wing
joiner ends until there is a tight fit.
(2) Align and epoxy the two main wing joiners together. Hold tight until the glue sets.
You'll notice that there is dihedral angle cut into the joiners so make sure they are
perfectly lined up.
(5) Apply epoxy to one half of one side of both the main and rear wing joiners and
glue them to one wing half. Make sure the dihedral angle is correct and that they
are slid in all the way.
-4-
(6) After the joiners have dried, apply epoxy where shown. The wing roots, the
wing joiners and inside the other wing joiner slot should be evenly covered with
epoxy.
(9) Drill two 8mm holes into the wing joiners for the dowel rods.
(7) Slide the two wing halves together slowly and wipe off any excess glue. Hold
the two wing halves firmly together with tape until the epoxy has cured.
(10)
Epoxy the
Iwo
dowel
rods
into
the
holes.
Make sure they are
all
the way
in.
(8) Once dry, remove the tape. Position the front joiner as shown. The flat edge of
the joiner should line up with the top of the wing. next, remove and epoxy in
that same position Let cure.
(11) Position the wing center cover on the bottom of the wing. Apply Cyanoacrylate
glue under the edges and hold until it dries.
-5-
(12) Epoxy in the main servo tray where shown
(15) Screw in the wing bolts half way into the wing bolt mounting block Apply ink
or paint to the heads of the two bolts Next center the wing and set it onto the
bolts This will mark where you need to drill
(13) Test fit the wing bolt mounting block to the inside of the fuselage The blind
nuts should face down
(16) After the epoxy has cured place the wing into the fuselage as shown Put the
front in first aligning the dowel rods in the holes Once in place lower the back
into position
(14) Epoxy the wing bolt mounting block in This is a high stress point and extra
care should be taken to ensure a strong joint
(17) Place the wing mounting brace onto the wing as shown and center the wing
and brace with the fuselage NOTE The two indentations on the brace should
face up PlastiZap it on
-6-
(18) Drill two 4mm holes 90° from the top wing surface for the wing bolts where
the paint marks are.
(21) Epoxy the aileron servo tray mount into the rear section of the wing servo
mount and then epoxy in the tray.
COCKPIT/CANOPY ASSEMBLY
(19) Assemble the wing bolts as shown (bolt — washer — wing — o-ring) and
temporarily fasten down the wing. Check for good fit and then remove.
(A)
Cockpit,
....................................
.1
(B)
Canopy
.....................................
.1
(C)
Cockpit Mounts
................................
.4
(D) 3x8mm Self-Tapping Screws .......................... .4
(20) Trial fit the aileron servo tray mount and tray to the wing. NOTE: The front
edge should
be
on the
wood,
therefore,
you
will
have
to
trim
away a little
covering for a good fit.
(1) Epoxy the four cockpit mounts to the fuselage as shown. Be careful when
gluing the rear mounts to only glue them to the wing mounting brace.
-7-
LANDING GEAR INSTALLATION
(2) Once the epoxy has cured, position the cockpit on the fuselage Make 4 small
holes where cockpit mounts are located Attach with the 4 small self-tapping
screws Do not glue the cockpit
(A)
Main
Gear
......
.1
(B) Rubber Shock Absorber. ..... .1
(C)
4mmx30mm
Screw
.......
.2
(D) 4mm
Washer
.......
.4
(E) 4mm Nut .... ...... .6
(F)
4mm Nylon
Nut..........
.2
(G) Wheel
.............
.2
(H) Wheel Pants . . .2
(1) 4mmx40mm Screw . . .2
(J)
3mmx12mm Screw
........
.2
(K)
3mm
Washer
.........
.2
(L) 3mm Nut .......... .2
(M) Plastic Collar ..... ..... .2
(3) Trail fit the canopy to the cockpit If necessary, trim for a perfect fit Apply a thin
bead of Cyanoacrylate glue to the cockpit and attach and hold the canopy until
(1) Remove the cockpit and the wing Place the two 4mmx40mm screws with the
4mm washers into the two landing gear holes that are located inside of the front
fuselage section
(4) Apply the black striping tape to the edge around the canopy.
(2) Thread two 4mm nuts onto the two screws and tighten Next place the rubber
shock absorber over the screws.
-8-
(3) Now place the main gear (angled side facing back) over the screws and secure
it with two 4mm nylon nuts NOTE tighten the nuts all the way and then
loosen them both one turn This will give the gear the correct shock absorbing
qualities
(6) Place the 3mm screw/washer into the top hole of the wheel pants from the
inside And then attach it to the top hole of the main gear using the 3mm nut
(4) Next take the two wheel pants and drill two holes in each one The first hole
should be at the indent (4mm in diameter) The second should be 3/8 above
the first and smaller (3mm diameter)
(7) Flare open the pants and insert the wheel assembly Install the 4mm nut and
tighten holding the inside nut with needle nose pliers
(5) Arrange the above parts as shown and then assemble together Do this twice
Place screw locking compound on the threads when installing the nuts
(8) Make sure that both wheels rotate freely If they do not trim away the plastic as
needed Or if need be, loosen the nuts unscrew the wheel screw, and
retighten
-9-
Loading...