Construction Manual
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Page 9
noted on the plans.
Start with WS3, measuring and notching around WH7 for a perfect
fit. When satisfied with the fit, temporarily tape it to the trailing
edge to hold it in position.
Now work with WS4, measuring
and cutting as necessary to
perfectly fit between the back of
the leading edge sheeting, and
the front of WS4.
Also you'll see that WS4 has a
cutout for the main gear and the
gear's mounting straps. Make
sure these are properly lined up as shown here.
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, WH7 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 40 - Wing Assembly (cap strips)
Just as you did on the top side, it's
time to install the cap strips from
BP11 and BP12 on the exposed ribs.
Step 41 - Wing Assembly (remove jig dowels)
Now it's time to free the wing from the jig assembly. Easily pop the
dowels from the J2, J4 and J6 supports. Then you should be able
to slide the dowels out of the wing half.
If you've been a touch careless with your glue and managed to
glue the dowel to one of the ribs, usually you can free the dowel
by grabbing one of the exposed ends with a pair pf pliers, then
rotating it slightly to pop loose the glue joint.
Step 42 - Wing Assembly (sand R10)
Grab your sanding block and it's time to true up the end of the
wing. Carefully sand away any excess sheeting, leading and trailing
edge stock or any of the spar that protrudes past R10.
It should be a smooth, flush surface.
Step 43 - Wing Assembly (T1)
Locate one of the T1s from LP2.
The tabs in T1 are pushed into
the two dowel holes and the
center cutout of R10.
Glue this in place, making sure it
is held perfectly perpendicular to
the surface of R10.
Step 44 - Wing Assembly (T2)
Locate two of the T2s from
BP7. Although the pieces are
identical, there is a top and
bottom and you can tell those
by the etched guidelines. When
glued in place on both sides of
T1, the guidelines should be
visible to aid in the installation
Step 36 - Wing Assembly (bottom spar)
Locate one length of 1/4" x
36" square basswood stick.
Measure and cut 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 have to sand here and there,
as well as wiggle the basswood 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.
Make sure it is completely seated in the slot of each rib. Use care
when pushing down - sometime it's better to reach underneath the
ribs and use more of a pinch to seat the spar in places.
Step 37 - Wing Assembly (trailing edge sheeting)
Locate the length of 1/16" sheeting you cut to a 1-3/4"width back
when sheeting the top of the wing.
Now you'll use the same techniques to fit the trailing edge sheeting
to the bottom surface. Measure and cutout a notch to perfectly fit
around the WH7 piece you installed earlier. Remember you can
always take wood off, but it's tricky to put back on, so take your
time and "sneak up" on it, little by little until you have a good fit.
When satisfied, glue this strip to each of the ribs, the trailing edge
and where it contacts WH7.
Step 38 - Wing Assembly (leading edge sheeting)
Locate another 1/16" x 4" x 36" sheet of uncut balsa.
Again, cut this sheet to length - roughly 28-1/2" long. Then you'll
need to measure and cut the angle needed to for this piece of
sheeting.
It will need butt-up against the leading edge and wrap around to
roughly 1/2-way covering the top spar. This is a straight taper, so
take your time, measure, measure, measure, double-check, then
only when happy - it's time to cut.
As the sheeting we get can vary in density, you might have to
apply a bit of Windex® glass cleaner to loosen up the grain. Soak
the outer side of the wood to expand the fibers. Now hold it to
curvature needed, then use a hair dryer or covering heat-gun to
help “set” the balsa’s bend as it dries. Once dry, the you can glue
it in position.
Glue it to the leading edge first, then to each of the ribs and finally
to the top spar.
Step 39 - Wing Assembly (center sheeting)
Locate WS3 and WS4 from BP12.
Just as you did with the top side,
you'll cut and glue this in place to
form the center sheeting.
Again, these pieces
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
