Tuff Birds
Super Tough Wings & Planes
Specifications:
Ÿ WingSpan: 1500MM
Ÿ All-Up-Weight: ~750 gms
Ÿ CG Location: 55MM from Leading edge
(spar location)
Whats Included:
Ÿ EPP Fuselage
Ÿ 2 Main EPS Wing Panels.
Ÿ 2 Polyhedral EPS Wing Tips
Ÿ Coro Parts (4) (Stab, Fin, Left/Right Fuse Sides)
Ÿ Laser cut Aeroply sheet
Ÿ ~500mm 6x2MM Carbon Fiber Strip
Ÿ Aluminium Spar ( 1000mm )
Ÿ Pushrods 2x 600mm each.
Linkage Connectors
Ÿ Battery Strap, Paper Knife
Ÿ 2x Adhesive backed Lamination sheet.
Ÿ 2x Pushrod Guides
Ÿ 2x CF Rod10cm ea
Ÿ 4x Rubber Bands
Ÿ Sand Paper
Ÿ Instructional Manual
Ÿ 2 Nos
Requires:
Ÿ 4-6 Channel Programmable Radio (Tx-Rx)
Ÿ 2200-3300mah 3S Lipo
Ÿ 20-30Amp Brushless ESC
Ÿ 2 Nos 9gms Servo
Ÿ Brushless Motor 22XX or 28XX series.
Ÿ 7-8inch propellor
Building Tools:
Ÿ Hot Glue Gun and Glue Sticks
Ÿ Cyanoacrylate Glue ( FeviKwik etc )
Ÿ Screwdrivers & Allen Key
Ÿ Paper Tape & Clear Packing Tape
Ÿ An Iron ( If Laminating )
Ÿ Soldering Iron and Solder Wire
Ÿ Ruler , Pen and a Flat Working Table
Congratulations on your purchase of the
TuffBirds Tuffstar 1500MM Trainer Airplane
Kit.. Hope these build instructions help you
complete the build. Though the build itself
doesn't take much time, just be sure to double
check everything before gluing or cutting.
The Tuffstar* is a great flier, and makes a
wonderful first time trainer with its slow and
predicable flight.
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Ver 1.0 25 Dec 2017
TuffStar*
1500MM EPP 3 Channel Trainer Airplane
BUILD INSTRUCTIONS
Tuff Birds
Super Tough Wings & Planes
Lightly Sand the Wing EPS Wing Panels to
smoothen the surface, so that the laminate
adheres well. Use the supplied sand paper to
lightly sand both sides of the Main wing panels
and the Polyhedral tips.
Unpack and lay out everything from the kit. Identify all
the parts . Note and mark the Left and Right Polyhedral
Wing Tips. The Main wing panels are the same for Left
and Right side, but the Wing Tips are cut so that they
are angled upwards when glued to the Mainwing
panels. In case you find anything missing, stop and
contact us before proceeding with the build.
1. Layout and Identify the parts.
2. Sand the EPS Wing Panels
Measure and cut the supplied adhesive backed
laminate sheet to fit. One sheet should do one
main panel and one Polyhedral tip. Peel of the
backing paper and laminate the wing . Try to avoid
any air bubbles. You may use an old plastic
credit/debit card to squeeze out any bubbles. Trim
the excess laminate from the sides when done.
3. Laminate the EPS Wing Panels
The polyhedral Wing Tips need to be Glued to
the main Panel. Each Wing tip has one side that
is cut at an angle. Use a bead of hot glue to glue
the tips to the main wings. Try to keep the height
the tips the same for both wings.
4. Glue the EPS Wing Tips
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Ver 1.0 25 Dec 2017
TuffStar*
1500MM EPP 3 Channel Trainer Airplane
Wing Tips
Wing Tips
Wing Panel
BUILD INSTRUCTIONS
Tuff Birds
Super Tough Wings & Planes
TuffStar*
1500MM EPP 3 Channel Trainer Airplane
Test fit the main wing spar in the wing panels.
Insert the spar gently with a twisting motion so as
to not damage the wing. The spar is a tight fit in the
wing.
5. Test fit the spar in the main wing slot.
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Ver 1.0 25 Dec 2017
Spar
With the Spar inserted into the wing, glue the
wooden Ribs to the both the wing root ends. Be
careful not to glue in the spars. The spar is inserted
in this step only for alignment of the spar hole.
6. Glue the wooden ribs to the wing root
The trailing edge of the wing root has to be cut of
to make the wing sit on the fuselage. The cut is
approximately 50MM wide ( fuselage width ) and
goes up to the wooden ribs glues earlier.
7. Cut the trailing edge of the wing root.
Congratulations.
The Wing is Completed !
BUILD INSTRUCTIONS
Tuff Birds
Super Tough Wings & Planes
The 6x2MM Carbon Strip has to be installed at
the bottom of the fuselage, towards the tail.
Measure and mark the center of the fuselage,
draw a line and install the spar vertically inside
the fuselage. Be sure to keep the fuselage on a
flat surface to avoid any twists.
11.Install servos
Mark and cut one flute on the Stab and Rudder
to make the Elevator and Rudder. Install the Stab
in the slit in the fuselage. Cut out the notch for
the rudder in the fuse and cut out . Be sure to
keep the Stab parellel with the wings and the
rudder perpendicular to the stab.
Hinge the Stabilizer and Rudder, Install the
Stabilizer and rudder as shown. Be sure to keep
the Vertifcal fin centered on the fuselage and
perpendicular to the stabilizer .
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Ver 1.0 25 Dec 2017
TuffStar*
1500MM EPP 3 Channel Trainer Airplane
10. Hinge & install Stab & Rudder1
9. Cut and install the spar on the fuselage
Because the way a Hot wire CNC cuts the foam
there is about a 1 MM slit in 2 places of the
fuselage. One is at the bottom of the battery bay
and one is at the center above the battery bay.
Use Hot glue to fill and glue the joints. Be sure to
lay the fuselage on a flat surface to avoid any
twists.
8. Glue the Fuselage Cuts
Fuselage Cuts
BUILD INSTRUCTIONS
Tuff Birds
Super Tough Wings & Planes
15 Wiring Diagram
Motor
ESC
BATTERY
RX
Rudder
Elevator
PROP
CH 1
CH 2
CH 3
FPV Gear
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Ver 1.0 25 Dec 2017
TuffStar*
1500MM EPP 3 Channel Trainer Airplane
Install the Pushrods and the Pushrod guides.
Glue the guides to the fuselage to remove any
slop from the linkage. Glue the control horns to
the Rudder and elevator.
13. Install the Control Linkages
14. Install the motor mount & battery tray
12. Install coro side doubler
To make the wing more secure, we have
provided rubber band method for wing
attachment. Glue the 3MM Ply reinforcement
ply discs in place and use the 4MM Carbon rods
and rubber bands to secure the wing.
Common Problems:
1. CG too far back. Airplane will not fly tail heavy. A good sign you are tail heavy is you can’t control the plane
or the plane won’t stay trimmed. When you try to loop the plane will roll over. Add weight to the nose to see if
the problems resolve. It is not uncommon to need an extra oz or two of lead depending on how light you build.
2. Too much movement in the elevons so the plane stalls on launch as you pull up on the elevator. This is a
very common problem!!!! May be combined or confused with tail heavy airplane symptoms.
3.Loose servos in the foam, linkages and push rods that flex, and poor leverage with push rods not installed per
plans, elevons are too soft and twisting.
BUILD INSTRUCTIONS
Tuff Birds
Super Tough Wings & Planes
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Ver 1.0 25 Dec 2017
Essential Preflight Checks:
1. Check CG. #1 Check. DO NOT FLY If you don't get this
right.
2. Check Elevon Mixing
3. Check Neutral Trim
4. Check throws.
5. Check Prop direction and thrust
6. Check for any slop in Elevon/linkage Connectors
First Flight Checks:
1. Fly in a open ground with no obstacles.
2. For the first flights have someone experienced do the
checks and trim out the model
3. Launch the model with about 50-80% power and INTO the
wind.
4. Remember - Safety first. Fly Safely and responsibly.
5. Check TX/RX Range.
Have fun and Enjoy. But fly responsibly. Find out a large open field, free from trees, buildings, obstructions
and people. Ensure you comply with local regulation laws.
Before flying your model, it is recommended you have an experienced flier from your region test fly the
model and trim it out for you . In case you have no such help, do not despair.
We suggest you go and do some computer simulation practice ( Realflight G4.5 , Phoenix etc ) afterwards this
airplane should be easy enough for you to fly.
Follow all of the Preflight checks mentioned below. Double check the control surfaces. They should all be
neutral and check again for control reversing. Check for wind direction. The airplane is always launched and
landed against the wind. So move to a location in your field from where you have a clear area ahead against
the wind to launch.
Always keep the model within sight and within the confines of your flying field.
The TuffBirds Tuffstar has been Designed, prototyped, tested and manufactured in India by Vortex-RC. All
Contents are copyright , and no part may be copied, or duplicated in anyf orm without the written permission
from Team Vortex-RC.
Visit us at and www.Vortex-RC.com www.TuffBirds.in
TuffStar*
1500MM EPP 3 Channel Trainer Airplane
16 Final Checks
Check the throws. Check the neutral. Check the
throw direction. Reverse channels if needed.
Adjust battery position to get the CG on the
spar.
CG Location
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