Building
file:///C|/Users/Frank/Documents/Demon/dem2.html[6/14/2011 4:30:56 PM]
Fuselage:
1. Using a 30" long PVC fuselage "blank" measure, mark, and cut out rear fuselage taper as shown on drawing 2.
The Dagger has no down thrust or right thrust.
2. Measure, mark and cut out the radio access hole as shown on drawing 2, leaving a 3/8" lip between the radio
access hole and fuselage side for strength. If you’re using a utility knife or saw (rather tough) this can be
made easier by drilling a 1/4" hole in each corner and cutting between them.
3. Measure, mark and cut out for the wing spar slot in the fuselage (see drawing #2). Insure the slot is cut big
enough to allow the yardstick to seat completely flush with outside surface of fuselage bottom, yet not too big
as to be sloppy!
NOTE:
The fit of your wing is dependent on how accurately you cut the spar slot!
4. Use some course grit sandpaper or a file to get all the white fuzzies off and to help clean up the cut edges.
Tail Feathers:
1. Refer to drawing 6 for the best layout we have come up with to get the most parts (and spare parts) from
one 4'x 8' sheet of Coroplast®.
2. Cut out horizontal and vertical tail feathers as shown on drawing 4.
3. Elevator and rudder are created by cutting out ONE SIDE ONLY of the hinge line corrugation. This can be a
little tricky. We use an adjustable blade, box opener type knife and straight edge. Wrapping an X-acto® knife
with masking tape leaving just the tip exposed will work also.
Can you believe it? The tail feathers are done already! Let’s attach them to the fuselage.
1. Fabricate 2 horizontal, and one vertical stab attach doublers as shown on drawing 7, from the PVC scrap
removed from the fuselage cutouts.
2. Fabricate a tailskid as shown on drawing 7 from the PVC scrap removed from the rear fuselage cutout.
NOTE:
Exact doubler hole location measurements are not given because this is not critical, and could change
slightly from plane to plane. When positioning the doublers and tailskid, keep in mind that the screws will go
through the Coroplast® very easily in the middle of a corrugation, and will almost certainly go crooked at the
edge of a corrugation.
3. Drill 1/16" pilot holes in doublers and tailskid.
4. Using the doublers and tailskid as templates, drill 1/16" holes in the fuselage for each screw attach location.
Enlarge holes IN FUSELAGE ONLY to 1/8".
6. When satisfied with positioning, fasten tail feathers to fuselage using sheet metal screws, self-tapping into
doublers and tail skid.
NOTE:
Dowel scraps can be used in the corrugations at the attach points to prevent Coroplast® crush.
6. Optional panel edging can be added to the stab leading edges for dress up and to keep dirt & fuel out if
desired.