Tuff Birds

Super Tough Wings & Planes

TuffStar*
1500MM EPP 3 Channel Trainer Airplane

Congratulations on your purchase of the Whats Included:

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.
Specifications:
Ÿ WingSpan: 1500MM
Ÿ All-Up-Weight: ~750 gms
Ÿ CG Location: 55MM from Leading edge
(spar location)
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.
Ÿ 2 Nos 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

Requires:
Building Tools:
Ÿ 4-6 Channel Programmable Radio (Tx-Rx)
Ÿ 2200-3300mah 3S Lipo Ÿ Hot Glue Gun and Glue Sticks
Ÿ 20-30Amp Brushless ESC Ÿ Cyanoacrylate Glue ( FeviKwik etc )
Ÿ 2 Nos 9gms Servo Ÿ Screwdrivers & Allen Key
Ÿ Brushless Motor 22XX or 28XX series. Ÿ Paper Tape & Clear Packing Tape
Ÿ 7-8inch propellor Ÿ An Iron ( If Laminating )
Ÿ Soldering Iron and Solder Wire
Ÿ Ruler , Pen and a Flat Working Table

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Tuff Birds
Super Tough Wings & Planes
TuffStar*
1500MM EPP 3 Channel Trainer Airplane

BUILD INSTRUCTIONS

1. Layout and Identify the parts.

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.

2. Sand the EPS Wing Panels

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.

3. Laminate 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.

4. Glue the EPS Wing Tips

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.

Wing Tips Wing Panel Wing Tips

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Tuff Birds
Super Tough Wings & Planes
TuffStar*
1500MM EPP 3 Channel Trainer Airplane

BUILD INSTRUCTIONS

5. Test fit the spar in the main wing slot.

Test fit the main wing spar in the wing panels.
Spar Insert the spar gently with a twisting motion so as
to not damage the wing. The spar is a tight fit in the
wing.

6. Glue the wooden ribs to the wing root

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.

7. Cut the trailing edge of 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.

Congratulations.
The Wing is Completed !
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Tuff Birds
Super Tough Wings & Planes
TuffStar*
1500MM EPP 3 Channel Trainer Airplane

BUILD INSTRUCTIONS

8. Glue the Fuselage Cuts

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
Fuselage Cuts
lay the fuselage on a flat surface to avoid any
twists.

9. Cut and install the spar on the fuselage

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.

10. Hinge & install Stab & Rudder

1
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 .

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.

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Tuff Birds
Super Tough Wings & Planes
TuffStar*
1500MM EPP 3 Channel Trainer Airplane

BUILD INSTRUCTIONS
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.

13. Install the Control Linkages

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.

14. Install the motor mount & battery tray

15 Wiring Diagram

FPV Gear
PROP

Motor ESC BATTERY

Elevator
CH 3
CH 2
RX
Rudder CH 1

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Tuff Birds
Super Tough Wings & Planes
TuffStar*
1500MM EPP 3 Channel Trainer Airplane

BUILD INSTRUCTIONS

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

Essential Preflight Checks: First Flight Checks:

1. Check CG. #1 Check. DO NOT FLY If you don't get this 1. Fly in a open ground with no obstacles.
right. 2. For the first flights have someone experienced do the
2. Check Elevon Mixing checks and trim out the model
3. Check Neutral Trim 3. Launch the model with about 50-80% power and INTO the
4. Check throws. wind.
5. Check Prop direction and thrust 4. Remember - Safety first. Fly Safely and responsibly.
6. Check for any slop in Elevon/linkage Connectors 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.

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.

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 www.Vortex-RC.com and www.TuffBirds.in

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