Tuff Birds TuffStar Instructional Manual

Brand: Tuff Birds

Model: TuffStar

Type: Instructional Manual

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.

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

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

Ver 1.0 25 Dec 2017

TuffStar*

1500MM EPP 3 Channel Trainer Airplane

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.

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 .

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

Rudder

Elevator

PROP

CH 1

CH 2

CH 3

FPV Gear

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

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

Tuff Birds TuffStar Instructional Manual

Brand: Tuff Birds

Model: TuffStar

Type: Instructional Manual

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Tuff Birds TuffStar Instructional Manual

Tuff Birds TuffStar Instructional Manual

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