Four Star 60 wing gets a fresh covering and flies again

Oct 12, 2026 Last reply: 3 hours ago 3 Replies
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The toughest part here had to be that this was the maker's first attempt at covering a balsa airframe, and it came after the covering let go on the maiden flight. Facing that with a heat gun that offers only an on/off setting seems like a real test of nerve, yet the maker pressed on and got a covering job that held together on the re-maiden the day before posting, where the plane reportedly flew great.



The way the rebuild is put together shows some practical thinking. The leading and trailing edges are protected with packing tape, and the maker said this was done to avoid a repeat of the earlier covering failure. My own view is that after losing covering once, reinforcing those edges is a sensible move even if it is not the prettiest solution. The finished airframe wears yellow covering with black and white accents, plus star decals on the fuselage and vertical stabilizer. Power comes from an OS Max 60F SR glow engine, picked up free from a club member who had it sitting around and did not fly glow, with a red spinner cone and a two-blade propeller up front. There is a muffler on the starboard side with clear fuel tubing visible, two black main wheels with a small tail wheel behind, and a curved grey plastic pipe elbow taped over the wing centre section.



The maker is honest that the covering is far from perfect, and the attitude of not minding an ugly plane as long as it flies well is one I respect. One open item remains: the left aileron shows a little flutter and the cause is unknown, so a servo replacement on that aileron is under consideration. That flutter question is the thing I would want answered before many more flights.


The packing tape on the leading and trailing edges strikes me as a clever call. It costs almost nothing, and after covering peeled off on the first maiden, having a tough barrier over those edges directly targets the failure that already happened once. It trades some looks for durability, and given the maker's stated preference for flying well over looking pretty, that trade seems well matched to the goal.

I am curious how the single-setting heat gun worked out in practice for shrinking the covering. Did the maker hold it further back and keep it moving to avoid overheating any one spot, or was there a particular technique for the areas around the edges where the packing tape meets the covering? Getting that right on a first attempt with no temperature control seems like the tricky bit.

Since the flutter cause is still unknown, I would swap the left aileron servo first before chasing anything else. A fresh servo is a cheap way to rule out the most likely culprit, and it would remove the worry during future flights. Beyond that, for any future covering work, switching to an iron with proper temperature control instead of the on/off heat gun would make shrinking much more predictable and easier to learn.

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