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         Construction Manual 

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Page 7

Step 21 - Wing Assembly (WS1 & WS2)

Locate one WS1 and 

one WS2 from BP11. 

These are used for the 

center sheeting, between 

the leading and trailing 

edges.

Note that they are both 

purposely made a little 

long, so you'll need to 

trim them to get a perfect 

fit.

Also note that the outer (curved) edges of these pieces will overlap 

R3 by approximately a 1/8" as noted on the plans.

Start with WS2, measuring and notching around WH6 for a perfect 

fit. When satisfied with the fit, temporarily tape it to the trailing 

edge to hold it in position.

Now work with WS1, measuring and cutting as necessary to 

perfectly fit between the back of the leading edge sheeting, and 

the front of WS2.

When satisfied with how it all looks, remove the pieces, the tape 

and then glue these sheets in position. Make sure they are glued to 

all the ribs, to the top spar, WH6 and where they touch the leading 

and trailing edge sheeting. It should all be one smooth sheet that 

follows the airfoil shape of the wing.

Step 22 - Wing Assembly (top cap strips)

Cut into BP11 and 

BP12 are a bunch of 

1/4" strips. These are 

cap strips and should 

be applied to the top 

of each of the exposed 

ribs (R4 - R10).

As there are two 

lengths of pre-cut 

strips, use the shortest 

one that's appropriate 

for each rib. Each strip 

should be centered on the rib and run from the rear of the leading 

edge sheeting to the front of the trailing edge sheeting.

Measure, cut, and glue each strip in position.

When you get to R10, the strip should be positioned so it's flush 

with R10's outer edge.

Step 23 - Wing Assembly (flip the wing over)

Once all the glue has 

cured from the previous 

step, it's time to work 

on the other side. To flip 

the wing over, carefully 

apply a touch of upward 

pressure where the jig's 

dowels snap into the J2, 

and J4 jigs. You should 

find that the dowels pop 

out and you're left with 

an assembly that can be flipped over. Before popping the dowels 

back into the jigs, you'll need to remove the center J4 jig. Once 

you've snapped the dowels back in place, you can find the shorter 

J6 jig you made. This should be used to 

support the rear dowel, about half-way along 

the wing's length.

Also remove any/all of the J8 clips you might 

have used to hold ribs in place. If you don't 

remove those now, some could get trapped 

inside the wing after sheeting is applied.

Step 24 - Wing Assembly (R2A & R3A)

Locate one R2A and one R3A 

from LP1.

This is glued to the outer sides 

of R2 and R3 respectively, 

making sure the cutouts are 

aligned as shown in this photo.

Step 25 - Wing Assembly (R2A & R3A)

Locate one WH5A 

and one WH5B from 

LP1.

These are glued in 

between the WH3 

and WH4 pieces 

already installed, and 

they should be right 

up against the pre-cut hole.

WH5A is on the inner side, WH5B on the outer side.

Step 26 - Wing Assembly (WH7)

Locate one WH7 from LP1.

This fits into the pre-cut 

grooves on the rear portion 

of  the R1 and R2 ribs.

Again, this has the engraved 

circle that should be up 

against the root rib and closer 

to the leading edge. This will 

position the pre-cut circle towards the root rib, as shown here. Glue 

WH7 to the ribs and to the WH3 and WH4 pieces already installed.

Step 27 - Wing Assembly (MG3)

Locate two MG3s from LP1.

These are glued one on 

top of the other, then this 

assembly is glued into the 

square cutouts of R2/R2A.

Push it in from the R2 side 

and use epoxy for this step.

Take care to keep the pre-cut 

circle clear of glue. The main 

gear wire will extend into this piece in the next few steps.

Step 28 - Wing Assembly (MG1)

Locate four MG1s from LP1 and LP2. Also locate one of the pre-

bent main gear wires.

The MG1s are glued on top of each other to form a large, thick 

Summary of Contents for Kaos

Page 1: ...atteries wheels etc throughout the building process You must correctly install all R C and other components so that the model operates correctly on the ground and in the air Installation shown in the...

Page 2: ...t 1 4 x 4 x 24 balsa 4 BP8 laser cut 1 16 x 4 x 24 balsa 2 BP9 laser cut 1 16 x 4 x 24 balsa 2 BP10 laser cut 1 16 x 4 x 24 balsa 2 BP11 laser cut 1 16 x 4 x 24 balsa 2 BP12 laser cut 1 16 x 4 x 24 ba...

Page 3: ...anual and online All photos shown in this manual are of different Kaos 60 prototypes Several pieces may have changed slightly with improvements we ve made so parts may look a little different in some...

Page 4: ...to 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...

Page 5: ...along the wing Step 9 Wing Assembly SW2 Locate two SW2s from LP1 and LP2 These are installed the same way as the previous SW pieces just doing it twice You are paying attention to where those etched...

Page 6: ...ood to get it to fit into the slots It is a tight fit Once you re satisfied with how it fits remove it then glue it in position to each rib and to where it contacts the upper portions of SW1 and SW2 M...

Page 7: ...apply a touch of upward pressure where the jig s dowels snap into the J2 and J4 jigs You should find that the dowels pop out and you re left with an assembly that can be flipped over Before popping th...

Page 8: ...ghtly sand the trailing edge so it will continue the airfoil shape Step 33 Wing Assembly dowels Now it s time to mark and drill the leading edge to accept the wing hold dowel Using the two 1 4 pre cut...

Page 9: ...it to length giving yourself a 1 4 or so extra on each end This is used as the bottom spar and will fit into the top cutout of each rib It is STRONGLY recommended that you dry fit this first You might...

Page 10: ...sure everything fits properly and the root ribs in each wing half are touching along their entire length when assembled into a single wing Take your time and get a good fit that doesn t require a lot...

Page 11: ...ding edge Next is to cut and install the leading edge pieces Check your scrap pile to see if you have the proper length first but if not use an uncut length of 1 4 x 1 2 x 36 balsa strip Glue these in...

Page 12: ...fore to complete the elevator halves Prepare your work area Now tape the vertical fin rudder plan and a fresh piece of waxed paper on your building board Step 69 Vertical Fin Assembly VF1 VF2 VF3 Loca...

Page 13: ...as the glue cures Step 80 Fuselage Assembly F5 Locate F5 from LP5 This is attached to the rear of TR4 as shown here Pay attention to the orientation Again make sure it s held at a 90 angle to TR4 as...

Page 14: ...form the fuselage side sheeting Refer to the diagram on the fuselage plan sheets on how these notch together You ll use the same techniques that you used when edge gluing sheeting together for the wi...

Page 15: ...osition but the middle of F2 should line up with the middle of the F2 on the plans Basically what we re looking for here is the fuselage to be lined up on the centerline of the plans as well as front...

Page 16: ...106 Fuselage Assembly stab supports Using scrap 1 4 square balsa cut 4 supports for the stab These will be glued where the stab contacts the inner surface of the fuselage sides You ll glue two on the...

Page 17: ...t works of art and match each other exactly Smooth out the edges of the fuselage Because of the 1 8 sheeting and the 1 8 basswood support installed around the fuselage s perimeter you can be a little...

Page 18: ...artially pushed up through the white mounting block Slip the steering arm in place then push the nose gear wire all the way through the arm and the block Stop when the wire is flush with the top of th...

Page 19: ...a bit of medium CA glue to permanently glue the joiner into both halves making sure the completed leading edge of the elevator is perfectly straight and flat Control horns servo pushrod installation...

Page 20: ...he entire airframe with the covering finish of your choice Note that if you re powering with an electric motor you ll need to make a hole for the cooling air to escape the bottom of the fuselage near...

Page 21: ...ans rather than making large changes electronically at the radio By moving the position of the clevis at the control horn toward the outermost hole you will decrease the amount of control throw of the...

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