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F.8L Falco Construction Manual
10–1
Revision 4, March 1, 2002
Chapter 10
Woodworking Methods
Introduction
This chapter will cover the basic techniques you will be using to build the Falco. We will discuss
methods that have been used for years, and we will also tell you about many techniques that Falco
builders have found to be helpful. If you find a nice way of doing things, please let us know!
Scarf Joints
The scarf joint is one of the most important joints that you will be doing for the wood structure of
the Falco. The wood must be machined accurately because the strength of the joint depends upon
maximum contact between the surfaces to be glued. You should also consider the properties of
the glue being used. Some glues (epoxies and Aerolite) have good gap filling characteristics and
others (resorcinol and Weldwood plastic resin) do not. Remember also to consider that clamping
pressures vary from one glue to another.
There are several important requirements for the scarf joints. First, the slope of the scarf joint is
of primary importance. A slope not steeper than 1 in 15 is considered ideal. It is best if you can
make all of your scarf joints with a 1 to 15 slope. You will have to make up a scarfing jig anyway,
so it is usually simpler to make all of the scarf joints the same. The outer eighth of the depth of
the spar caps may be no steeper than 1 in 15, while adjacent layers may have steeper slopes, but
we would caution against this practice. Take your time and do it right. Of all of the wood
structure of the Falco, the most important are the spar caps. Other things such as the fuselage
frame laminated bows are less critical, and you may use a steeper slope for these parts (such as 1 to
12) if you wish. Plywood scarf joints may be 1 to 12, but with a minimum of 1 to 10.
Correct
Incorrect
Incorrect
Figure 1
A second requirement of a scarf joint is the direction of the grain in relation to the scarf joint.
Since end-grain gluing is more difficult (and results in a weaker joint) than side-grain gluing, it
follows that where cross grain within the specified acceptable limits is present, all scarf cuts must
Summary of Contents for F.8L Falco
Page 1: ...F 8L Falco Construction Manual...
Page 7: ...l F 8L Falco Construction Manual Revision 4 March 1 2002...
Page 21: ...l F 8L Falco Construction Manual 1 8 Revision 4 March 1 2002...
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