Top Flite Stinson Reliant, User Manual

Page: 31 / 60

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4. Removing additional cross bracing as you
proceed, use epoxy to glue the laser-cut 1/8" plywood
vertical former bracing to both sides of formers 3, 4
and 5. Where necessary, cut notches in the 1/8" x 3/8"
balsa main stringers to accommodate the bracing.
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5. Use 30-minute epoxy to glue the second laser-
cut 1/8" plywood former brace F4C to the front of
F4C on the top of former 4.
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6. Glue together the die-cut 1/8" plywood left and
right top deck . Sand both pieces flat and even, then
glue a piece of leftover 1/8" x 1/4" basswood to the
bottom of the assembly across the glue joint, 1/2" aft
of the front edge. Use a ballpoint pen to mark the
partially die-cut lines on the bottom of the right top
deck on the top, so you will know where to cut for the
instrument panel when instructed to do so. Test fit the
assembly to the forward fuse sides.
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7. Mark a line on the inside of both forward fuse
sides 1/4" from the front edge. Mark a line on the
inside of the top deck that aligns with the lines you
marked on the forward fuse sides (the parts must be
fitted together to see where to mark the lines on the
top deck).
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8. Cut three firewall reinforcement sticks from
a 1/4" x 3/8" x 36" basswood stick and use 30-minute
epoxy to glue them to the forward fuse sides and the
top deck along the lines you marked.
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9. Once more, test fit the left and right bottom
deck and the left and right forward fuse sides to the
fuse and hold in position with C-clamps. Add the top
deck. Make certain you understand how the parts fit
together and join to the fuse. Make adjustments
where required for good fitting joints.
Refer to this photo for the following two steps.
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10. Remove the parts from the fuse. Use
30-minute epoxy to glue the left fuse side and the left
bottom deck to each other and to the fuse.
Do not
apply glue to the left fuse side or to the left bottom
deck forward of former 3. This will be done later when
it’s time to join the firewall. Proceed to the next step
before the epoxy fully cures.
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11. Mix up a new batch of 30-minute epoxy and
glue the right fuse side and the right bottom deck in
position the same way. Add the top deck to the
assembly to help with alignment, but do not apply
any glue. Though there is no glue forward of F3, note
the C-clamps holding the fuse sides to the bottom
decks. This is to help establish the correct curvature
in the fuse sides. Do not remove the C-clamps until
the epoxy is fully cured.
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12. Make the center bottom deck by gluing
together two 1/8" x 3" x 24" balsa sheets to make a
1/8" x 6" x 24" balsa sheet. Trim the center bottom
deck to fit between the left and right bottom deck.
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13. Test fit the center bottom deck in the fuse.
Make certain that when the center bottom deck is
glued to the right and left bottom decks, the distance
between the insides of the forward fuse sides will be
7-3/32" (the same width as the firewall). Glue the
center bottom deck into position. Glue a 1/4" x 3/8"
basswood stick across the bottom deck in alignment
with the sticks on the forward fuse sides.
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14. Position the 1/4" x 5-11/16" x 7-3/32" firewall
over the firewall drawing on the plan. Use a ballpoint
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