Page 4
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Construction Manual
When finished you should
have 4 jigs which look like
these.
These wing jig supports
are designed to be used
on two types of building
boards. If you use a
traditional board (where
you use pins to hold
things in place) use thumbtacks through the tiny pre-cut holes to
hold them in place.
For magnetic boards, pop-out the pre-cut circles, and use the
included magnets. Note - there are 12 magnets included in
your Kaos. Since you'll use the three larger jigs first, push the
magnets into those first - BUT DON'T GLUE THEM IN PLACE.
The undercutting of the circles should provide more than enough
friction stay in place. Plus, you'll be re-purposing some of these
magnets later on in the build.
Lastly, wick some thin C/A into the "cupped'
areas in the top of each of these mounts. THIS
IS VERY IMPORTANT! When these are used in
the upcoming steps, they are designed so the
1/4" dowels will have a slight "snap" to help
lock them in place. Without wicking in thin C/A to harden these
areas, they could splinter when removing the dowels.
Step 4 - Wing Assembly (dowels)
Locate both 1/4" x 36" long
dowels. Trim 4" off each dowel
and set these shorter pieces
aside. They'll be used as the
wing-hold dowels later on in the
construction.
Step 5 - Wing Assembly (position jig supports)
Place the jig supports in position over the wing plan.
There are three spots which are noted by a dotted
line on the plan. The two J2 jigs are placed on the
ends, with their flat surface facing the ribs. The
center J4 jig is placed mid-way, and make sure that
the large cutout is positioned towards the wing's
leading edge.
Note that the
placement of
the outer J2
jig will be up-
against the R10
rib, as shown on
the plans.
Step 6 - Wing Assembly (position ribs)
Locate one set of ribs - R1 through R10. R1 and R2 are on LP1, and
the others are on BP3 and BP4.
Push these onto the front and the rear jig dowels. Make sure
you slide them on in numerical order, and pay attention to their
orientation. The etched rib number should be at the top when
properly placed. Group the R1-R5 ribs together on the left side
IT IS VERY IMPORTANT THAT YOU ASSEMBLE THE KAOS
60 KIT IN THE ORDER DESCRIBED. SKIPPING FORWARD
IN THE STEPS COULD LEAVE YOU WITHOUT THE PROPER
LENGTHS OF WOOD TO FINISH THE KIT.
WE’VE INCLUDED ENOUGH WOOD TO EASILY COMPLETE
THIS KIT, BUT YOU MUST TAKE CARE TO PROPERLY
MEASURE AND NOT WASTE WOOD WHEN CUTTING.
Let’s begin construction by working on the starboard (right)
wing of your Kaos 60.
Prepare your work area
You’ll need a flat building
surface that is a minimum
of 36” long. Position the
starboard wing plan over the
surface and tape into position.
Tear off a length of waxed
paper long enough to cover
the right wing plan and tape that into position, over the plan.
Step 1 - Alignment triangles
Pre-cut into LP4 are three triangles.
Two are 90° angles, one inside the
other. The third is only used when
aligning the wing's root rib. It's
clearly marked as such so don't
worry about that one for now.
However, punch out the two 90° triangles as those can be used to
vertically align any of the parts in the construction of your Kaos.
LP4 also includes foot pieces that can be used with the triangles to
hold both triangles vertical hands-free.
Step 2 - Wing Assembly (J2 end jig)
Locate both J1s and J2s from LP2,
and four J5's located in LP1, LP2
and LP5.
Glue two J5's into J2 as shown
here.
Then glue J1 to this assembly to
complete one of the wing's J2 end
jigs. Make sure the pieces are firmly
pushed together to make a 90°
bracket.
Now do the same to complete the
other J2 end jig.
Step 3 - Wing Assembly (J4 & J6 jigs)
Locate J3 and J4 from LP3, J6 and J7 from LP5, and three J5's
located in LP1, LP2 and LP5.
Glue two J5's into J4, then glue J3 to this assembly to complete
one of the wing's J2 center jigs. Make sure the pieces are firmly
pushed together to make a 90° bracket.
Now do the same to complete the other shorter J6 center jig.
