GREAT PLANES Ultra Sport 40 Plus, Instruction Manual

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11. Join two 19" [480mm] sheets together. Tape them
together with masking tape, then flip the sheets over and
glue the other side with thin CA. Let dry, remove the
masking tape and lightly sand the joint. Do this twice so that
you have one sheet for each side of the stab.
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12. Sheet the top and bottom of the stab by applying
slow-curing glue such as 30-minute epoxy or wood glue to
the top and bottom of the stab structure and then placing the
structure between the 1/16" [1.6mm] sheets you just joined.
Use weights to apply pressure on the sandwich. Make sure
the stab is placed on a flat surface while the glue cures.
Sheet the top and bottom of the elevators following the
same procedure using the leftover 1/16" [1.6mm] sheets.
Again, make sure the elevators are placed on a flat surface
while the glue cures. If you wish to do so, you can round the
tip of the elevators.
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13. Sand the edges of the stab and the elevators square
using a bar sander. Mate the stabilizer and elevators to
check the fit. Shape the leading edge of the stab and the
leading edge of the elevator counter balance to obtain the
shape shown in the plan’s cross section. Do not shape the
leading edge of the elevators yet.
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14. Locate the center of the trailing edge of the stab.
Place a T-pin on the center at each end of the stab. Lay a
straight edge against the pins and draw a centerline on the
trailing edge of the stab. Repeat this procedure for the
leading edge of the two elevators. A great tool for marking
the center of the trailing edge is the Great Planes Precision
Hinge Marking Tool (GPMR4005).
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15. Using the plans as your reference, mark the location
for the hinges on the T.E. of the stab and the L.E. of the two
elevator halves.
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16. Cut the hinge slots in the stab and elevators using a
#11 blade inserted in your hobby knife. Begin by carefully
cutting a very shallow slit at the hinge location to accurately
establish the hinge slot. Make three of four more cuts, going
a little deeper each time. As you cut, slide the knife from side
to side until the slot has reached the proper depth and width
for the hinge.
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