ASSEMBLY INSTRUCTIONS

90-Day Limited WarrantyIf 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 optionof our authorized U.S. repair facility, Hobby Services - without charge. Our liability does not include cost of shipping to us. However, Hobby Services will payshipping expenses lo return your model to you. You must provide proof of purchase, such as your original purchase invoice or receipt, for your model'swarranty 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 resultingloss of kits. engines, accessories, etc.

Repair ServiceYour 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: (217) 398-0007. Please follow the instructions below when returning your model. This will help our experienced technicians torepair 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 f u l l r e tu rn 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 anominal cost. Repair charges and postage may be prepaid or billed COD. Additional postage charges will be applied for non-warraiuy returns All repairsshipped outside the United States must be prepaid in U.S. funds only All pictures, descriptions and specifications found in this instruction manual and onthe 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 enginequickly and easily. To use this mount, please replace the following steps in the manual withthese:

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 and3/8" 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 andattaching them to the firewall using four 6-32 x 3/4" machine screws with washers. Donot 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 4mmcollar. 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 wheelpointing straight ahead.

4mmCollars

5. On page 18, after step 46, once the engine in properly positioned, tighten the engine mount tothe 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 hardware 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 offersnearly all the excitement of piloting a real airplane...and develops skills that will take you anywhere youwant in your new hobby.

Know Your Model's PartsTake a moment now to match the box contents with the items listed below. Following the Avistar 40'sassembly 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.

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Other Items You'll NeedGluesChoose any 6-minute epoxy, such as Great Planes®Pro'" Epoxy, which has been formulated especiallyfor R/C model building. Epoxies offer a strongbond and a variety of curing times suited for everystep of assembly. You'll also need an instant-settingCA (cyanoacrylate), a thicker CA+, and a 30-minuteepoxy, plus rubbing alcohol and paper towels foreasy epoxy cleanup.

HardwareTools and accessories required for assembly:

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

Model EnginePower your Avistar with any high-quality, .40-sizemodel engine. The O.S.® .40 LA and SuperTigre®GS-40 are just a few examples. Look for featuressuch as easy break-in, easy starting, efficientcarburetion and low maintenance. Check themanufacturer's recommendations for propellers touse with your engine.

Radio EquipmentTo let you send the commands that control yourAvistar 40's "flight path," you'll need a 4-channelaircraft 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 on-board your model and need to be cushioned fromjolts and vibration. One-half inch thick foamrubber sheets are available for this purpose.

Getting Ready f o r FlightYour Hobbico Avistar 40 trainer is ready for takeoffin as little as 15-20 hours. Your hobby dealer orflying instructor can help you decide whataccessories you'll need for flight. Most are one-timeonly purchases—and your instructor will probablyallow you to use his field box until you can outfityour own with a glow plug starter, fuel bulb orpump, and "chicken stick" or electric starter. You

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

Other General Items Required:Masking TapeEpoxy Brushes

T-PinsClothes pinsSandpaperFoam RubberMixing Sticks

Felt-Tip MarkerStringPaper TowelsStandard ScrewdriverThread Locking Compound

Epoxy Mixing Cups Wing Seating Tape

Find A Flying InstructorThe best way to begin flying your Avistar 40 is withan experienced R/C pilot or flying instructor atyour side. You'll learn faster, relax those in-flightjitters and avoid risking your model before you'retruly ready to solo.

Where do you find an instructor? Ask at your localhobby shop. They'll have information about flyingclubs in your area whose membership includesqualified instructors. You can also join theAcademy of Model Aeronautics (AMA), a 165,000member-strong national organization with morethan 2,500 chartered clubs across the country.Through any one of them, instructor trainingprograms and insured newcomer training areavailable. Contact the AMA at the address or phonenumber below:

Academy of Model Aeronautics5151 East Memorial Drive

Muncie, IN 47302Toll Free: (800) 435-9262

Fax: (765) 741-0057Web Site: http://www.modelaircraft.org

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Please follow these safety precautions:

Before you fly1. 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 care1. 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 startthe engine— NOT your fingers.

6. Make sure that the wires from your starter andglow plug clip cannot become tangled with thespinning propeller.

7. Do not stand at the side of the propeller whenyou 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 thespinning propeller.

90-Day Limited WarrantyIf you, as the original owner of this model, discoverdefects in parts or workmanship within 90 days ofpurchase, Hobbico will repair or replace it—at theoption of our authorized U.S. repair facility, HobbyServices—without charge. Our liability does notinclude cost of shipping to us. However, HobbyServices will pay shipping expenses to return yourmodel to you.

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

This warranty does not apply to damage or defectscaused by misuse or improper assembly, service orshipment. Modifications, alterations or repair byanyone other than Hobby Services voids thiswarranty. We are sorry, but we cannot beresponsible for crash damage and/or resulting lossof kits, engines, accessories, etc.

Repair ServiceYour Avistar 40 must be returned directly to HobbyServices for warranty work. The address is:

Hobby Services,Attn: Service Department

1610 Interstate Drive, Champaign, IL 61822Phone: (217) 398-0007

Please follow the instructions when returning yourmodel. This will help our experienced techniciansto 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 aTHOROUGH, written explanation of theproblem and service needed. If you expect therepair to be covered under warranty, alsoinclude your proof of purchase.

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

If your model is past the 90-day warranty period oris excluded from warranty coverage, you can stillreceive repair service through Hobby Services at anominal cost. Repair charges and postage may beprepaid or billed COD. Additional postage chargeswill be applied for non-warranty returns. Allrepairs shipped outside the United States must beprepaid in U.S. funds only.

All pictures, descriptions and specificationsfound in this instruction manual and on theproduct package are subject to change withoutnotice. Hobbico maintains no responsibility forinadvertent errors.

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Q Find the two 1/8" (3mm) die-cut plywood wingjoiners. Draw a center line on both sides of theplywood wing joiners and balsa aileron servo traymounting blocks. Use one plywood joiner as atemplate to mark the wing dihedral angle on bothof the balsa 5/16" x5/16" x 1-1/2" (8mm x 8mm x38mm) aileron servo tray mounting blocks. Putthese mounting blocks aside for use later.

Orientation of the wing joinersQ Arrange the two "V-shaped plywood wingjoiners in the same orientation as they will beglued together.

Gluing the wing joiner

Q Mix approximately l/4oz. (7.5ml) of30-minuteepoxy. Using a mixing stick or epoxy brush, applyan 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 joinerstogether firmly. The excess epoxy must be removedbefore it cures as described in the next step.

Removing the excess epoxyl-l Excess epoxy will be squeezed out of the seamsbetween the joiners and must be removed beforethe epoxy is allowed to cure. Use a paper towel andrubbing alcohol to remove the excess epoxy.Be careful not to disturb the alignment of thejoiner pieces.

Test fit the wing joiner

After the epoxy has cured and the clothes pinshave been removed, test fit the wing joiner in bothwings by sliding the joiner into the joiner cavity inthe wing. The joiner should slide in with a littleresistance up to the centerline drawn on the bothsides of the joiner.

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Sanding the joinerCl If the wing joiner will not Fit in the cavity, lightlysand the excess epoxy and uneven surface jointsfrom the joiner edges and sides. Caution: A snug fitis desirable between the joiner and the wing cavity.Do not sand excessively.

Viewing the wing dihedralCl Pay close attention to the orientation of the wingjoiner in relation to the dihedral of the wings.

Marking the wing cavity

1-1 Lay the wing halves on the work surface with theflat side facing up. Remove the precut balsa from theroot rib. Using the measurements in the sketch, trimaway the balsa sheeting from the bottom of the wingto allow for the installation of the aileron servo.

Gluing the joiner in the wing1-1 Mix l/4oz. (7.5ml) of 30-minute epoxy to gluethe joiner into one wing half. Use a mixing stick orepoxy brush to apply epoxy to all four sides of thejoiner cavity wall. Insert the joiner into the cavityup to the centerline marked on the joiner plate. Besure you are installing the joiner in the correctorientation to the wing. It should angle upwardswhen installed correctly. Clean the excess epoxyfrom the wing root rib. You must be sure all theexcess glue is removed from the wing root or thewings will not fit together correctly. Allow enoughtime for the epoxy to fully cure before proceedingto the next step.

Applying the epoxyl-l Mix l/2oz. (14.5ml) of 30-minute epoxy andapply to the wing root rib and inside the joinercavity of the second wing half.

Joining the wing halves

Q Assemble the two wing halves with the tightestseam possible. No gaps should be showing betweenthe two wing halves. Clean the excess epoxy fromthe outside of the wing using a paper towel andrubbing alcohol. Tape the wing halves together withmasking tape. Set the wing aside to cure.

Cutting the mounting blocks

l-l Find the aileron servo tray and the two balsaservo tray mounting blocks and position themwith the marked dihedral line up. Using a sharphobby knife, cut the angle out of the block. Thisangle will be placed against the wing when theservo tray is installed.

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Assembling the servo tray

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

Q Test fit the aileron servo into the servo tray andthe hole cut in the bottom side of the wing. Enlargeeither hole, if needed, with a hobby knife or a fine-toothed file until a proper fit is achieved.

Removing the covering

Q Position the aileron servo tray so it is centeredover the opening made in the wing. Using a felt-tipmarker, trace the outside of the servo traymounting block onto the wing. Use a sharp hobbyknife to remove the covering for the mountingblocks. Use care not to cut into the underlyingbalsa 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 theservo tray to the bottom side of the wing. Applyequal amounts of epoxy to the mounting blocks onboth ends of the servo tray. Attach the servo tray onthe bottom of the wing with the servo wire harnessnotch facing the trailing edge of the wing. Themounting blocks should be attached to the wingsheeting where the covering was removed and notto the plastic wing covering. Allow the epoxy tofully cure before proceeding to the next step.

Aileron installation

HINGES

TORQUEROD

l-l Test fit the ailerons on the wing with the hingesinstalled. Check for free movement in bothdirections. There should be no binding. Use atoothpick to push 30-minute epoxy down thetorque-rod holes in each aileron. Fit the aileron inplace. There should Be virtually no gap when theaileron is fully seated. If the aileron will not fullyseat, use a hobby knife to clean the hinge slots andtry it again. Glue in the hinges by wicking 4 dropsof thin CA into each side of the hinges.

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Installing the servo tray Constructing the tail section

Mix l/8oz. (3.5ml) of 6-minute epoxy to glue theservo tray into the fuselage. Apply epoxy to allfuselage parts that will come in contact with theservo tray.

Q Locate the horizontal stabilizer slot under thecovering on the tail section of the fuselage bypressing lightly with your finger. The slot will belocated on both sides of the tail. Using a hobbyknife, carefully remove the covering exposing theslots. Note: Do not cut into the balsa woodsheeting around the slot.

Installing the wing dowels

LI The wing dowel holes are predrilled. Locate thefour round holes (two on each side of the fuselage)and remove the covering over each hole. Insert thetwo wood dowels into the fuselage. The shorterdowel is installed towards the tail of the airplane.Install the dowel caps onto the dowels using four2.5mm x 8mm sheet metal screws. You may need tohold one screw with a pliers while installing theother side.

Vertical stabilizer slot coveringQ Using your finger, locate the vertical stabilizerslot on the top of the fuselage. Remove thecovering with a hobby knife in the same manner asfor the horizontal stabilizer slots. This will allowbetter viewing access when centering thehorizontal stabilizer.

Finding the centerline

A A

Q Locate the horizontal stabilizer and draw acenterline on the side with the three color graphics.Insert the stabilizer into the tail section with the lineshowing through the vertical stabilizer slot.

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Preparing to install the stabilizer

EQUAL MEASUREMENTS

Q Attach a piece of string with a pin to the center ofthe firewall as shown. The string should be aminimum of 31-1/2" (800mm) in length. Stretchthe string to the corner of the horizontal stabilizer.The distance from the pin to the horizontalstabilizer must be the same on both sides. Thismethod will adjust the horizontal stabilizer to a90" angle to the centerline of the aircraft.

Tracing the fuselage outline

U Using a felt-tip pen, trace a line around the tail ofthe airplane on the top and bottom of thehorizontal stabilizer.

Removing the covering

Q Using a sharp hobby knife, cut 1/32" [1mm]inside the lines made with the felt-tip pen andremove the covering from the center of thehorizontal stabilizer. Do not cut into the balsasheeting on the horizontal stabilizer.

Installing the stabilizerQ Mix l/4oz. (7.5ml) of30-minute epoxy to installthe horizontal stabilizer. Using a mixing stick,place glue inside the horizontal stabilizer slot onall sides including the horizontal stabilizer mount.Insert the horizontal stabilizer and clean off theexcess epoxy that squeezes out of the joint with apaper towel and rubbing alcohol. Adjust alignmentas shown in the previous step. Set the fuselageaside to cure.

Preparing the vertical stabilizer

Q Locate the vertical stabilizer. Draw a line on bothsides even with the bottom of the fin as shown inthe sketch. Cutting 1/32" (1mm) below the line andthrough the covering only, remove the coveringfrom the base of the vertical fin.Important: Do not cut into the balsa fin root.

T-PIN

STRINGSTRING

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Installing the vertical stabilizer

90° 90°

Fin Alignment 90° Sketch

Q Mix l/4oz. (7.5ml) of 30-minute epoxy to gluethe vertical stabilizer in place. Using a mixing stick,apply epoxy to the top of the horizontal stabilizerthrough the vertical stabilizer slot. Apply epoxy tothe sides and bottom surfaces of the fin base thathave balsa wood exposed. Insert the verticalstabilizer into the slot, making sure the fin root isseated firmly on the horizontal stabilizer. Check fora perpendicular angle between the fin and thestabilizer when viewed from the back. It is criticalthat the fin remains perpendicular while the epoxyis curing. Masking tape may be required to holdthe fin during this time.

Installing the rudder and elevator hinges

Q Test fit the rudder and elevator on the fin andstabilizer with the hinges installed. Use the sketch

in "Installing the Ailerons" as a guide. Check forfree movement in both directions. There should beno binding. Glue in the hinges by wicking 4 dropsof thin CA into each side of the hinges.

Locations of the control horns

l-l Note the locations and alignment of the controlhorns in both the photo and the illustration beforemarking and drilling.

Control horn alignmentHINGE LINE

CORRECT INCORRECT11

Attaching the elevator control horn Locating the rudder exit hole

Locate a nylon control horn. Place the horn onthe bottom of the elevator. Position it 1" (25.4mm)from center and aligned with the leading edge asshown in the sketch and photo. Mark the two holeswith a felt-tip pen. The holes of the control hornshould line-up with the gap between the rudderand the vertical stabilizer. Drill two 1/16" (1.5mm)holes through the balsa elevator. Insert two 2-56 x5/8" machine screws through the control horn andelevator into the control horn back plate on theopposite side of the elevator. Tighten the screwsbut do not crush the balsa.

QThe precut rudder pushrod exit hole is located onthe same side as the rudder control horn, under thecovering. Locate the exit hole by gently runningyour finger down the top of the fuselage. Using ahobby knife, remove the covering from the rudderpushrod exit hole. Do not remove the covering fromthe exit hole on the opposite side.

Cutting the elevator exit hole

Installing the rudder hornLocate the other nylon control horn. Place thecontrol horn on the left side of the rudder, 1" (25mm)from the top of the hinged stabilizer as shown in thephoto on the previous page. Mark the two holes witha felt-tip pen. Drill two 1/16" (1.5mm) holes throughthe rudder. Use two machine screws 2-56 x 5/8" toattach the control horn.

Q The precut elevator pushrod exit hole is locatedon the same side of the fuselage as the elevatorcontrol horn, beneath the covering. Locate the exithole by gently running your finger down the side ofthe fuselage over the covering. Using a hobby knife,remove the covering from the elevator pushrodexit hole. Do not remove the covering from the exithole on the opposite side of the fuselage.

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Installing the landing gear

Q On the bottom of the fuselage, 9-3/4" (248mm)from the engine compartment, there is a channellocated under the covering. Locate this channel byrunning your finger over the covering on the bottomof the fuselage. Using a hobby knife remove thecovering from this channel. To protect the channelfrom fuel damage, place several drops of thin CAalong the channel and wipe with a paper towel.

Installing the struts

Q Locate the two chromed landing struts and placethem in the pre-drilled holes inside the channel onthe bottom side of the fuselage. Place two nylonlanding gear straps over the landing gear struts. Usinga felt-tip pen, mark the location of the strapmounting holes onto the bottom of the fuselage. Drillthe four holes using a 1/16" (1.5mm) drill bit. Mountthe nylon landing gear straps using four #2x3/8" self-tapping screws to the bottom of the fuselage over thestruts. The struts should be flush with the bottom ofthe fuselage.

Mounting the wheels

Q Locate two foam wheels and four wheel collars.Place one wheel collar on each strut and secure itslocation using a 6-32 set screw. Place the wheel ontothe strut, followed by another wheel collar. Secure theadditional wheel collar with another 6-32 set screw.In total, you will have two wheel collars, two 6-32 setscrews and one wheel on each strut.

Q Locate the aluminum engine mount and attachit to the firewall using four 6-32 x 3/4" machinescrews and four #6 washers. The flat side of theengine mount will be towards the top of thefuselage as shown in the drawing and photo. Usethread locking compound on the screws to makesure they won't vibrate loose. Attach the nose gearmount to the firewall using two 6-32 x 3/4"machine screws.

Installing the nose gear

1-1 Place a wheel collar onto the nose gear strut.Insert the nose gear stem into the plastic nose gear

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holding bracket on the fuselage firewall. Press a5/32" wheel collar into the nylon steering arm.Make sure the hole in the arm lines up with thehole in the wheel collar. Place the nylon steeringarm between the plastic bracket and motor mount.Slide the nose gear stem into the motor mount.Lock the steering arm onto the flat spot of the nosegear by tightening the socket head screw on thefront of the arm. Insert a 14-1/8" (359mm) pushrodtube through the hole into the fuselage. Thepushrod tube must be flush with the firewall forthe steering to work properly. Wick thin CA aroundthe pushrod guide tube.

Installing the pushrod

Q Locate the 17-1/2" (445mm) wire control rod (nothreads) and make a 90-degree bend in one end1/2" from the end. Remove the steering arm fromthe nose gear assembly. Insert the bend into theinside hole of the steering control horn from thebottom. Slide the pushrod wire into the guide tubeand reassemble the nose gear assembly. Trim theremaining arm to allow for maximum steering.

Throttle control guideQ Insert the remaining plastic pushrod guide tubeinto the predrilled hole in the engine compartmentfirewall. Leaving 1/4" (6mm) of the tube showing,glue the throttle control tube into the firewall usingthin CA.

Insert the control rod

Q Install a 14-1/8" (360mm) pushrod tube into thefirewall for the throttle pushrod. Leave 1" (25mm) ofthe pushrod tube to extend forward of the firewall.Secure the pushrod tube using thin CA. Thread aclevis onto the 17-1/2" (440mm) pushrod using thesame technique as the aileron pushrods. Insert thepushrod into the tube as shown in the photo.

l-l Locate the two aluminum tubes that are used inthe fuel tank.

Bending the pressure line

Q Being careful not to kink the tube, bend one endof the longer tube to a 70 degree angle. It may behelpful to find a rigid object that can be used as aform to bend the tube around. Leave 1-1/2"(38mm) of straight tube at one end so it can easilybe inserted through the tank plug.

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Assembling the tank plug Installing the tank

U Locate the two stopper plates. Push the aluminumtubes through the smaller stopper disc and the backof the rubber plug. Place the larger stopper disc onthe opposite side and insert the 3 x 20mm machinescrew through the larger disc, the rubber plug andthen into the smaller disc. Do not tighten the screwat this time.

Final fuel tank assembly

Q Locate the metal fuel pick-up weight (oftenreferred to as the "clunk weight") and the mediumsilicone fuel tubing. Insert the fuel pick-up weightonto the fuel tubing. Compare the length of thefuel tank to the length of the fuel tubing and cutthe tubing so that the fuel pick-up weight on theend of the fuel tubing will not touch the end of thefuel tank. The plug assembly can now be insertedinto the tank. The pressure tube should beadjusted so the tube is pointed straight up justunder the top of the tank.

Caution: The pressure tube should be close but nottouching the top of the tank because the flow of fuelmay be interrupted and cause the engine to quit.The stopper discs on the rubber plug can betightened by turning the screw. Do not over tightenthe stopper plates or damage to the tank may occur.

(-1 Insert the fuel tank into the fuselage as shown inthe photo.

Orientation of the fuel ports

1-1 Note the locations of the fuel tubes. Cut two fuelline lengths, pressure line 4-1/2" (114mm) and fuelline 4" (101mm), from medium silicone fuel line(not included). Place the cut fuel lines over thecorrect tubes.

Mounting the engine

1-1 The photo shows an O.S. 40 LA engine mounted.Secure the engine by using two engine mounting

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brackets, four 4 x 15mm screws, four 4mm lockwashers and four 4mm nuts. The engine centerlinemust be in line with the fuselage centerline. Placethe engine on the mount and secure the engine withthe engine brackets. The lock washers should belocated on top of the bracket under the head of thescrew. The screws are secured by four 4mm nuts.Note: Thread locking compound is recommendedfor use on the engine mounting screws. Attach theclevis to the throttle arm in the hole closest to thecenter of the arm.

Attaching the muffler

Q Locate the muffler and mount it to the engine byusing the screws included with the engine. Theexhaust outlet should be pointing down and awayfrom the fuselage. Use the instructions includedwith the engine to make this adjustment.

Running the fuel line

Q Run the fuel lines to the proper locations on theengine (fuel line to the fuel inlet, pressure line tothe muffler).

Mounting the propeller and spinner

Q Slide the spinner backplate onto the crankshaft ofthe engine. Align the propeller with the two alignmentpegs on the backplate. Secure the propeller andbackplate to the engine using the washer and nutincluded with the engine. Use a wrench to tighten thenut. If the nut is even slightly loose, the propellercould come off and become a hazard.

Final spinner assemblyQ Place the spinner cone onto the backplate untilthey snap together. They must be aligned correctlyfor a proper fit. The spinner cone must not come incontact with the prop or fatigue and fracture of theprop may occur over a period of time. Insert both2 x 12mm self-tapping screws into the spinner andtighten firmly,

Radio Installation

Installing the receiver and battery

Q Wrap both the receiver and battery pack in foamrubber (not included). Using the supplied hook andloop material, attach the receiver and battery packto the radio gear tray using the photo as a guide.

Alignment Pegs

Alignment Pegs

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Installing the switchQ Cut a rectangular switch hole in the side of thefuselage opposite the exhaust using a hobby knife.Locate the receiver switch harness in the radiosystem and remove the face plate. Place the switchinto the hole with the switch facing outward. Putthe face plate over the switch and mark the screwholes with a felt-tip marker using the plate as atemplate. Drill the screw mounting holes using a1/16" (1.5mm) drill bit. Install the switch from theinside of the fuselage with the "on" position towardthe rear of the plane. If the switch should get hitwhile the plane is moving forward, it would notturn the receiver off. Secure the switch using thetwo screws supplied with the switch.

Preparing the servosQ Remove the servo arms and wheels from the threeservos. Install the rubber grommets that came withthe radio system onto the servos, following theinstructions included with your radio system.

Servo installation

1-1 Install the three servos from your radio system asshown in the photo. Refer to the radio manufacturer'smanual for more detailed instructions. Notice thelocation and orientation of each servo as well as theswitch location.Antenna Routing

STRAIN RELIEFINSIDE FUSELAGE

ANTENNA HOLDERAT THE TOP OF THE

VERTICAL STABILIZER

CUTCUT

RUBBERBAND

Q Drill a 1/16" (1.5mm) exit hole in the center of therear window 1" (25.4mm) down from the edge of the

radio compartment. Route the antenna under theplywood servo tray and up through the exit hole. Donot cut the antenna wire. The receiver is tuned to aspecific length of antenna. Use a medium T-pin toattach a rubber band to the top portion of thevertical stabilizer. Tie the antenna to the rubberband using tension to keep the antenna tight. Usecaution not to damage the antenna. A servo horncan be cut and used to hold the antenna in place atboth ends with less likelihood of damage to theantenna wire.

Q Locate the two 21-3/4" (555mm) outer pushrodtubes. Slide the tubes into the fuselage from theelevator and rudder pushrod exits. Enlarge theexits to allow the tubes to slide in easily. Don't gluethe tubes at this time.

Q Center the ailerons, then mark the pushrods atthe point where they meet the holes in the servoarm. Make a 90 degree bend down in the wires atthis mark.

T-PIN

17

Q Cut off the excess wire 3/8" (9.5mm) above thebend. Enlarge the servo horn holes with a 5/64"(2mm) drill bit. Insert the bent wire pushrods intothe servo horn from the upper side, then securethem with Nylon FasLink Pushrod Keepers.

Q Thread clevises onto the 26-3/4" (680mm)pushrods using the same technique as the aileronpushrods. Insert the pushrods into the rudder andelevator pushrod tubes as shown in the photo.Attach the clevises for both the elevator and rudderto the control horns as shown. (Both clevises areattached in the same locations.)

Q

0 Center the elevator, then mark the pushrodwhere it crosses the servo horn hole. Enlarge theservo horn hole with a 5/64" (2mm) drill bit. Make

a 90 degree bend in the pushrod at the mark (youmay want to disconnect the clevis from the elevatorcontrol horn to pull the pushrod wire out of thefuselage to make it easier to bend). Cut off theexcess wire 3/8" (9.5mm) above the bend. Insert thebent wire through the enlarged hole in the servohorn. Secure it in place with a nylon FasLink.

Q Repeat the above step for the rudder pushrod.

1-1 Adjust the height of the pushrod support so thepushrods can move freely without binding. Glue thebrace into position using medium CA. Slide thepushrod tubes so 1/8" (3mm) extends forward ofthe pushrod support. Glue the pushrod tubes to thebrace using thin CA. Be very careful not to get CAinto the tubes and accidentally glue the pushrodwires to the tubes. Glue the pushrod tubes to thefuselage using medium CA.

l-l With the radio on, move the throttle trim leverand control stick to the closed position, by pullingthem back (or downward) all the way. Manuallyclose the throttle on the carburetor completely.Tighten the set screw on the pushrod connector.Check throttle operation with the radio and makeadjustments to the linkage as necessary for smoothoperation from fully closed to fully open. Use theappropriate holes in the servo horn and throttlearm to provide the correct amount of throttlemovement and to prevent the servo from bindingat its end points.

Q Install the nose wheel using the same techniqueas the main wheels. Center the nose wheel andtighten the screw on the pushrod connector for thenose wheel steering.

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NOTE: This section is VERY important and mustNOT be omitted! A model that is not properlybalanced will be unstable and possibly unflyable.

Q Use a felt tip pen or a narrow strip of tape toaccurately mark the balance point on the bottom ofthe wing near both sides of the fuselage. Thebalance point (CG) on the Avistar 40 is located3-1/4" (83mm) back from the leading edge. This isthe point at which your model should balance foryour first flights. Later, you may experiment byshifting the balance up to 5/16" (8mm) forward orback to change the flying characteristics. Movingthe balance forward may improve the smoothnessand arrow-like tracking, but it may require morespeed for takeoff and make it more difficult to slowdown for landing. Moving the balance aft makes themodel more agile with a lighter and snappier feel.Please start at the location we recommend and donot at any time balance your model outside therecommended range.

Plug the aileron servo into the receiver. Mount thewing to the fuselage with #64 rubber bands. Theengine, muffler, propeller and fuel tank should alsobe mounted for the C.G. check.

With the fuel tank empty and the wing attached tothe fuselage, lift the model with your finger tips atthe balance point. If the tail drops when you lift,the model is "tail heavy" and you must move thebattery and/or the receiver toward the nose toachieve balance. If the nose drops, it's "nose heavy"and you must move the battery and/or receivertoward the tail to achieve balance. The C.G. isalways determined with the fuel tank empty.

Balance the model by shifting the receiver batteryand receiver, then test again. When balance isobtained note the position of the of the receiver,and the battery pack. If the balance cannot beachieved by positioning the battery and receiver,you may add stick-on lead weight to the tail ornose if required.

Confirm that the battery and receiver are securelywrapped in foam and secured so they cannot shiftduring flight or a rough landing.

IMPORTANT: After the model is 100% complete,recheck the balance.

IMPORTANT: Go back and check your installation.Be sure that all servo screws, horns and othercomponents are secure. Confirm that you haveinstalled the retainers on the screw lock connectors.

Apply a strip of 1/16" (1.5mm) thick foam wing-seating tape (not included) to the wing saddle.This tape provides a seal against dirt and exhaustoil and cushions the wing from vibration.

4-CHANNEL RADIO SETUP(STANDARD MODE 2)

ELEVATOR MOVES UP

RIGHT AILERON MOVES UP

LEFT AILERON MOVES DOWN

RUDDER MOVES RIGHT

CARBURETOR WIDE OPEN

Q Check the direction of all control functions. Theymust all move in the direction shown in the sketch.If not, change the position of the reversingswitches on your transmitter.

3-1/4" (83mm)

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Control Surface ThrowsWe recommend the following throws:

NOTE: Control throw (movement) is measuredat the trailing edge of the elevator, rudder andailerons. Hold a ruler vertically on yourworkbench or block it up on books to makethese measurements.

ELEVATOR: 3/8" up 3/8" down

RUDDER: 3/4" right 3/4" left

AILERONS: 5/16" up 5/16" downNOTE: The balance and control throws for theAvistar 40 have been thoroughly tested andrepresent the settings at which the Avistar 40flies best. Please set up your Avistar 40 to thespecifications listed. If, after a few flights, youwould like to adjust the throws to suit yourtaste, that's fine. Remember, "more is not better."

Note: If your radio system does not featureAdjustable Travel Volume (ATV's), you will have tomechanically adjust control surface throw.

Q Control throw adjustment: If you move the clevisat the control horn on the control surface towardthe outermost hole, you will decrease the amountof throw. If you move the clevis to a hole nearer thecontrol surface you will increase the amount ofthrow. If these adjustments do not provide thedesired throws, you may need to work with acombination of adjustments by repositioning thepushrod at the servo. If you move the pushrodtoward the splined shaft on the servo arm, it willdecrease the control surface throw - outward willincrease it.

Ground Stance

NOSETOO HIGH

NOSETOO LOW

LEVEL

Q "Eyeball" the side of the fuselage from 6 - 10 feetaway. If necessary adjust the height of the nose by

raising or lowering the nose gear wire so that yourmodel will sit pretty much level, as shown inthe sketches.

Once the correct ground stance is established,tighten the screws on both the steering arm andwheel collar on the flat spot of the nose gear wire tolock the nose gear strut in position. Use thread lockon both screws.

It is a good practice to periodically check the groundstance of your Avistar 40 - especially after a hardlanding. The wire landing gear is designed to absorbshock from rough landings but occasionally mayneed to be bent back into position.

Charge the BatteriesFollow the battery charging procedures in yourradio instruction manual. You should alwayscharge your transmitter and receiver batteries thenight before you go flying and at other times asrecommended by the radio manufacturer.

Balance the PropellerBalance your propellers carefully before flying. Anunbalanced prop is the single most significantcause of vibration. Not only will engine mountingscrews and bolts vibrate out, possibly withdisastrous effect, but vibration will also damageyour radio receiver and battery. Vibration willcause your fuel to foam, which will, in turn, causeyour engine to run lean or quit.

We use a Top Flite' Precision Magnetic PropBalancer'" (#TOPQ5700) in the workshop and keepa Great Planes Fingertip Balancer" (#GPMQ5000)in our flight box.

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Find a Safe Place to FlyThe best place to fly your R/C model is an AMA(Academy of Model Aeronautics) chartered clubfield. Ask your hobby shop dealer if there is such aclub in your area and join. Club fields are set up forR/C flying and that makes your outing safer andmore enjoyable. The AMA also can tell you thename of a club in your area. We recommend thatyou join AMA and a local club so you can have asafe place to fly and have insurance to cover you incase of a flying accident (The AMA address is listedon page 3 of this instruction book).

If a club and its flying site are not available, youneed to find a large, grassy area at least 6 milesaway from any other R/C radio operation like R/Cboats and R/C cars and away from houses,buildings and streets. A schoolyard may lookinviting but it is too close to people, power linesand possible radio interference.

Ground Check the ModelIf you are not thoroughly familiar with theoperation of R/C models, ask an experiencedmodeler to check that you have installed the radiocorrectly and all the control surfaces do what theyare supposed to. The engine operation also mustbe checked and the engine "broken-in" on theground by running the engine for at least two tanksof fuel. Follow the engine manufacturer'srecommendations for break-in. Check to makesure all screws remain tight, that the hinges aresecure and that the prop is on tight.

Range Check Your RadioWhenever you go to the flying field, you need tocheck the operational range of the radio before thefirst flight of the day. First, make sure no one else ison your frequency (channel). With your transmitterantenna collapsed and the receiver and transmitteron, you should be able to walk at least 100 feet awayfrom the model and still have control. Have a friendstand by your model and, while you work thecontrols, tell you what the control surfaces aredoing. Repeat this test with the engine running atvarious speeds with a helper holding the model. Ifthe control surfaces are not always acting correctly,do not fly! Find and correct the problem first. Look

for loose servo connections or corrosion, loosebolts that may cause vibration, a defective on/offswitch, low battery voltage or a defective cell, adamaged receiver antenna, or a receiver crystal thatmay have been damaged from a previous crash.

Engine Safety PrecautionsNOTE: Failure to follow these safety precautionsmay result in severe injury to yourself and others.

Keep all engine fuel in a safe place, away from highheat, sparks or flames as fuel is very flammable. Donot smoke near the engine or fuel; and rememberthat the engine exhaust gives off a great deal ofdeadly carbon monoxide. Do not run the engine ina closed room or garage.

Get help from an experienced pilot when learningto operate engines.

Use safety glasses when starting or running enginesand make all engine adjustments from behind therotating propeller.

Do not run the engine in an area of loose gravel orsand; the propeller may throw such material inyour face or eyes.

Keep your face and body as well as all spectatorsaway from the plane of rotation of the propeller asyou start and run the engine.

Keep items such as these away from the prop:loose clothing, shirt sleeves, ties, scarfs, long hairor loose objects such as pencils, screw drivers thatmay fall out of shirt or jacket pockets into the prop.

Use a "chicken stick" device or electric starter;follow instructions supplied with the starter orstick. Make certain the glow plug clip or connectoris secure so that it will not pop off or otherwise getinto the running propeller.

The engine gets hot! Do not touch it during or afteroperation. Make sure fuel lines are in goodcondition so fuel will not leak onto a hot enginecausing a fire.

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Your first flights should consist of mostly straightand level flight with gentle turns to keep the modelover the field. These flights will give you practice atcoordinating your control inputs and maintainingthe proper orientation of the airplane. Asmentioned earlier, turns are accomplished bybanking the aircraft with the ailerons, then gentlyadding some back stick (up elevator). Enough backstick should be held in to keep the aircraft at aconstant altitude. To stop turning, apply oppositeaileron (or rudder) to level the wings, then releasethe sticks. There is a memory aid that may helpkeep you out of trouble when the plane is flyingtoward you - "put the stick under the low wing." Inother words, move the stick in the direction of thelow wing to raise that wing. When you arecomfortable flying the aircraft, you can practiceusing the rudder along with the ailerons to"coordinate" the turns - usually, a small amount ofrudder applied in the direction of the turn willkeep the tail following in the exact same track asthe nose.

The most common mistake when learning to fly is"over control." Think of pressure instead of largemovements of the control sticks. Remember allAvistar 40's will recover from almost any overcontrol situation within 50 - 100 feet if you simplylet go of the sticks.

Add and practice one maneuver at a time, learninghow your Avistar 40 behaves in each maneuver.After you have several flights on your Avistar 40, it'stime to reward yourself with your first acrobaticmaneuver - a loop. Climb to a safe altitude andturn into the wind. Apply full throttle, level thewings, then slowly pull back on the elevator stick toabout 1/2 to 3/4 up elevator (depending on yourthrows) and hold this control input. After you goover the top and start down the back side of theloop, pull the throttle back to about half. This willkeep the stresses on the airplane low and theairspeed relatively constant. Keep holding "up"elevator until the plane is level, then slowly releasethe sticks. You're done! It's really that easy!

CAUTION (THIS APPLIES TO ALL R/CAIRPLANES): If, while flying, you notice anyunusual sounds, such as a low-pitched "buzz",this may indicate control surface "flutter".Because flutter can quickly destroy componentsof your airplane, any time you detect flutter youmust immediately cut the throttle and land theairplane! Check all servo grommets fordeterioration (this will indicate which surfacefluttered) and make sure all pushrod linkagesare slop-free. If it fluttered once, it will probablyflutter again under similar circumstances unlessyou can eliminate the slop or flexing in thelinkages. Here are some things which can resultin flutter: Excessive hinge gap; Not mountingcontrol horns solidly; Sloppy fit of clevis pin inhorn; Elasticity present in flexible plasticpushrods; Side-play of pushrod in guide tubecaused by tight bends; Sloppy fit of Z-bend inservo arm; Insufficient glue used when gluing inthe elevator joiner wire or aileron torque rod;Excessive flexing of aileron, caused by using toosoft balsa aileron; Excessive "play" or "backlash"in servo gears; and Insecure servo mounting.

Landing When it's time to land, fly a normal landing

pattern and approach as follows: Reduce thepower to about 1/4 and fly a downwind leg farenough out from the runway to allow you to makea gentle 180 degree turn. As you make the turn intothe wind for your final approach, pull the throttleback to idle. The Avistar 40 has a lot of lift so youwill need a slow, reliable idle in order to achievea nice, slow landing. Allow the plane to keepdescending on a gradual glide slope until you areabout 3 feet off the runway. Gradually apply a littleup elevator to flare for landing. You should applyjust enough up elevator to hold the plane just offthe runway while the excess speed bleeds off. TheAvistar 40 should settle onto the runway for a slow,slightly nose-high landing.

Good luck and have fun flying your Avistar 40, butalways stay in control and fly in a safe manner.