Building the Left Wing:
27...Pin the lower 1/4” sq. spar and the trailing edge to the left wing plan.
28...Cut the lower 1/16” sheet for the lower inboard end of the wing and glue in place between the trailing edge and the spar.
29...Glue the lower plywood dihedral brace to the front of the lower spar. Place the first W-1 rib into position. Use the dihedral
gauge to angle the top of this rib toward the tip and glue the rib into position
30...Glue the other W-1 rib and all of the W-2 ribs into position. These ribs should be 90 degrees to the building board.
31...Glue the aft center rib (W-4) into position.
32...Glue the top 1/4” sq. spar into position. The inboard end of the spar should end in the middle of W-4.
33...Glue the top plywood dihedral brace to the front of the top spar.
34...Glue the leading edge and the 3/32” sq. strips to the leading edge.
35...Add the 1/16” sheet to the inboard end of the wing between the spar and the trailing edge. Use three pieces of 1/16” sheet
to sheet the inboard top of the wing from the spar to the leading edge. These pieces go between the 3/32” sq. strips and not
on top of them.
36...Remove the wing from the plan and add the lower 1/16” sheet to the inboard end between the spar and the leading edge.
37...Trim and sand the spars, leading edge and the trailing edge flush with the last W-2 rib.
38...Glue the forward center rib W-5 into position.
Building the Right Wing:
39...Place the left wing into position on the end of the right wing plan. Place a spacer under the last W-2 rib to raise the tip
3 1/4” above the building board. The lower 1/16” plywood dihedral brace for the right wing should be flat against the plan.
Pin the left wing into this position.
40...Pin the lower spar and the trailing edge into position for the right wing. Glue the spar to the dihedral brace and glue the
trailing edge to the left wing.
41...Add the lower rear inboard sheet to the right wing and finish assembling the right wing as you did the left.
NOTE: When you sheet the top of the right wing you want to butt the sheet against W-4 and W-5. This will leave two slots
in the center of the wing for the engine pylon to plug into.
42...When the right wing is finished, sand the entire wing smooth and sand the leading edge round.
43...Cut the 3/4” triangle for the wing tips in half and glue to the ends of the wing. The front of the tip block should be flush
with the leading edge, and the bottom should be flush with the bottom of the W-2 rib. Sand the tip blocks to match the air
foil section of the ribs and then sand them smooth.
Building the Engine Pylon:
44...Place your engine mount on the firewall (P-3) and drill the mounting holes in the firewall. Place blind nuts into the holes and
secure with thin C/A glue being careful not to get any into the threads.
45...Glue P-3 to the front of P-1. You should have a small amount of right thrust (2 or 3 degrees). Down thrust is automatically
provided by the angle on the front of F-1.
46...Glue parts P-2 to each side of the pylon.
47...Place a small dot or square of masking tape over the back of the blind nuts in the left side of the firewall and glue the pylon
block into position. Sand the block to shape and sand the front and rear edges of the F-2 pieces round.
48...Test fit the pylon to the wing. It should fit all of the way into the slots with the bottom edges of the P-2 pieces making
contact with the wing center sheeting.
Building the Tip Floats:
49...Make the center keel of the tip floats by gluing parts T-1 and T-2 together.
50...Glue pieces T-3, T-4, T-5 and T-6 into the notches in the bottom of T-2. These parts should be 90 degrees to F-2 when
viewed from the bottom.
51...Glue one part T-7 to each side of the tip float. The front and rear should be flush with T-3 and T-6.
52...Sheet the bottom of the tip float with one piece of 1/16” sheet. Sheet the top with two pieces (one on each side) of 1/16”
sheet. Sand the sheet flush with the sides and the front and back of the float.
53...Cut the 1/2” sq. strip into 4 pieces and glue them to the front and rear of the tip floats. Sand the blocks to shape.
54...Round the four corners of the tip float mount plates (T-8).
55...Cover the tip floats and the mount plate with iron on covering.
Page 6
Summary of Contents for AQUA STAR HRR502
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