RE: Sig 4 star 40
I know a lot of people say the wings on the 4* 40's and 60"s are strong enough if built carefully, but I just don't like the flex and fragile appearance of the wings on those planes.
I just obtained a 4* 40 Kit. I plan to make a few changes. I will make another DH brace using 1/8" aircraft ply, and extend it at least one more bay into each wing. I will also add a second DH brace about 2/3 of the way back by cutting the Stock Sig DH brace thinner and gluing it into new notches. You may want to sheet the leading edge back to the first Spar top and bottom and add shear webs for 1/2 of the wingspan. The weight will go up an ounce or so, but I make up for the extra weight by using "Micafilm" which is 1/2 the weight of Monocote. I did about the same on my last 4* 60, except for the leading edge bit. My next 4* 60 will be built as above.
What I found out on my 4* 60 is that by making the inner 60% of the Strip Al. into Flaps, the plane was much easier to land as it did not float nearly as far. I plan on doing the same on my 4* 40 when I build it this winter. Just don't make the mistake I made on my 4 * 60, I increased the throw on my AL's and found out that the reduced drag of the outer 40% made it turn much quicker, so I wound up reducing the throw from the stock amount suggested in the plans, to get an easily controlable airplane. I believe the 4 * 40 will respond the same as the 4* 60 to the flaps.
Ralph