RE: Four Star 60 ARF assembly problems
A couple of other things that I had on mine that you did not mention. I tried using the nyrod pushrods and found them constantly binding. This put pressure on them inside the servo tray area. I had to add a brace to keep them in place. Finally I just swapped them out for regular steel pushrods and it works fine now. I also had a problem with the throttle cable bending because the cable sleeve wasn't long enough. Once I added some length and another brace inside the servo area it was OK. I am also running an OS91 surpass 4 stroke engine, and when it idled, the fuse cheeks vibrated so much that the botom front of the fuse started to split at the glue joints. I reglued the joints and put in a wooden dowel across the front and screwed it in between the cheeks using cowling screws. (You can just see it in front of the valve guides in the picture.) It was fine after that. I used a sullivan tail wheel assembly, but didnt have anything to really attach it to. So I took a wooden dowel, drilled a hole in the bottom and through where the stab glues on so I would have a good solid piece of wood to attach the tailwheel bracket to. As far as the block of wood in the fuse at the tail, I agree, it was a b**ch to get out. To get the servo wires through the wing, I use a piece of string with a hex nut tied to the end. It took a little doing, but it wasn't too hard to get it threaded through.
After all that though, I am really happy with the plane. I love flying it, and still get it out to the field once in a while.