9
q
8) Working with one outer wing panel and one
outer dihedral brace for now, test fit the dihedral
brace into the plywood box in the outer wing panel.
The brace should slide into the wing panel up to the
centerline. If it does not, remove the brace and
lightly sand the edges and tips of the brace until the
proper fit is obtained. See photo # 4 below.
Photo # 4
The dihedral brace is cut in the shape of a "V".
The "V" shape should face the top surface of
the wing (curved surface) when the brace is installed.
q
9) When satisfied with the fit of the dihedral
brace, remove it from the wing panel.
q
10) Mix a generous amount of Kwik Bond 5
Minute Epoxy. Apply a thin layer of epoxy inside
the plywood dihedral brace box and to only half of
the dihedral brace. Make sure to cover the top and
bottom as well as the sides, and use enough epoxy to
fill any gaps.
q
11) Slide the dihedral brace into the plywood
box up to the centerline. Remove any excess epoxy
before it dries using a paper towel and rubbing alco-
hol. Allow the epoxy to cure before proceeding.
q
12) Repeat steps # 8 - # 11 to install the second
outboard dihedral brace into the second outboard
wing panel.
JOINING THE OUTBOARD WING PANELS
q
13) Working with the right outboard wing panel
and the right inboard wing panel for now, test fit the
two wing panels together. With the inboard panel
flat on your workbench, the tip of the outer wing panel
should be 2-3/4” off the surface of the workbench.
This measurement should be taken at the trailing edge
of the outer panel where the tip begins. Use books or
a scrap piece of wood to hold the wing panel in the
proper position. It is also helpful to weight down the
inboard panel so it does not move. Magazines work
good for this. See figure # 2 at top right.
Figure # 2
The wing panels should fit together tight with
little or no gaps in the joint. If the joint is not
tight, remove the wing panels and lightly sand the
edges and tips of the dihedral brace. Test fit the wing
panels together once more. Repeat this until you are
satisfied with the fit of the wing panels.
q
14) Mix a generous amount of Kwik Bond 5
Minute Epoxy. Apply a thin layer of epoxy to the
exposed half of the dihedral brace, the inside of the
plywood box in the inboard wing panel and the entire
surface of both ribs. Make sure to use enough epoxy
to fill any gaps.
q
15) Slide the two wing panels together and care-
fully align them at the leading and trailing edges.
Align the wing panels as done in step # 13, keeping
the inboard panel flat and using a book or scrap wood
to hold the outboard panel at the proper height. Wipe
away any excess epoxy using a paper towel and rub-
bing alcohol and allow the epoxy to fully cure before
handling the wing.
After the epoxy has completely cured, use a ruler
and check the final dihedral angle of the out-
board panel. If it is not exactly 2-3/4”, that is okay.
When you join the opposite two panels together, make
sure that angle is the same angle as the first. To help
visualize this you can place the two sets of wing pan-
els next to each other to double check your work.
q
16) Repeat steps # 13 - # 15 to join the left out-
board wing panel and the left inboard wing panel.
Once that is complete you should have one right and
one left wing half.
JOINING THE WING HALVES
q
17) Using a ruler and a pen, locate and mark the
centerline of the center dihedral brace. Draw one ver-
tical line at this location on each side of the brace.
Outboard
Wing Panel
Dihedral
Brace
Flat Work Surface
Inboard Wing
Panel
Outboard
Wing Panel
2-3/4”
