Page 6
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Construction Manual
of some 30 minute epoxy. Remove the DH2 and DH1 parts, then
mix up enough 30 minute epoxy to Carefully spread a thin layer of
epoxy on the inside of the dihedral box of one wing half, and both
sides of one half of DH1.
Put a DH2 on the front and back of DH1 where you applied the
epoxy. Be careful to note the circle’s position on each DH2. Then
slide the DH1/DH2 sandwich into the wing’s box, making sure that
DH1 is angled upwards, toward the top of the wing. Push it in so
exactly half of DH1 is inside the wing half (both DH2’s should be
flush with R1 when seated properly).
Wipe off any excess epoxy with the paper towels and rubbing
alcohol mentioned earlier in this step.
Step 28 - Wing Assembly (join 2 wing halves)
Once the epoxy has cured
from the previous step, it’s
time to join the two wing
halves. Locate the other
DH2’s from BP1 and test
fit them into the right wing
half, as you did before.
Note that when you test fit
the pieces, together, the
wing halves should touch in
the middle, with both R1 pieces lining up with no twists.
After test fitting, it’s time to join the wing halves permanently with
a bit more 30 minute epoxy. Remove the DH2 and DH1 parts and
apply the epoxy as you did in the previous step, but also coat the
joining face of R1.
Now repeat the process you used in the previous step to attach the
DH1/DH2 sandwich in the right wing’s box.
Any twist in the alignment of the panels cannot be fixed after the
epoxy cures and will lead to a poor flying model. As the two wing
halves are close to mating, be sure that the tabs on WH5 and WH6
slide into the tabs on R2.
Using a couple of clamps,
hold R1 ribs firmly together
between the two wing halves.
Wipe off any excess epoxy
and remove the clamps only
after the epoxy has fully cured.
Also be sure to add glue to
WH5 and WH6 where they key
into the R2’s.
Step 29 - Wing Assembly (install WH6 and WH7)
Once the epoxy has cured from
the previous step, position the
wing with the top up and the
trailing edge closest to you.
Locate the 4 WH7’s from the
BP2 sheets. Glue one WH7 on
top of WH6 on the left side of
center, making sure that the holes line up, then one on the right.
Now glue a second WH6 on top of the first one on the left side,
then one on the right.
Step 30 - Wing Assembly (center sheeting)
Now the center sheeting
is applied to the
underside of the wing’s
center section.
Flip the wing so the
bottom is facing up and
apply the sheeting from
the center (R1) out to
R2, one half at a time. If
you look closely you’ll
find that R1 and R2 are
recessed slightly to allow this sheeting to fit flush with all the spars
and trailing edge.
Using the surplus 1/16” sheeting from the BH4 sheets, measure
and cut the sheeting to cover the opening between the R1 and R2
ribs. You will need 3 pieces per side:
• Two front sheets - these cover the gap between the lower-front
sub-spar and the front sheer webs
• Two mid sheets - these cover the gap between the rear sheer
webs and the lower-rear sub spar.
• Two rear sheets - these cover the gap between the lower-rear
sub spar and the trailing edge.
The rear sheets will have to be notched to clear the two tabs at the
back of R1 and R2.
Once satisfied with the fit, glue each of these sheeting pieces into
position.
If building as a 4ch model (with ailerons) the mid sheets will need
a hole cut into each of them to allow the aileron extension wires to
exit the wing (see plans). You can cut these now, or after the sheets
are installed.
Step 31 - Wing Assembly (remove tabs)
Remove the rear tabs on each of the ribs. The balsa tabs will
typically snap off, depending on the amount of glue used to attach
the trailing edge. The tabs on the plywood ribs (R1 & R2) will need
to be sawed/sanded to be removed.
Step 32 - Wing Assembly (sanding)
It’s time sand the wing to the proper shape. Start with a coarser
grit (80-100) to round the leading edge, shape the trailing edge,
and round the edges of the wing tips. Take care not to remove too
much, too quickly - you can always take more off, but you can’t put
it back on!
Switch to a finer grit (150-200) to smooth out the entire wing.
Step 33 - Wing Assembly (attaching WH1-WH4)
The front of the wing
is held in place with a
unique assembly that
we’re going to build now.
Position the wing with the
bottom surface up, and
the leading edge facing
you. Also locate both
WH1’s, the WH2, WH3
