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Instruction Manual F4U-1D Corsair
CARF-Models Ltd. [email protected]
1. Main Gear and Gear Door Installation
To start with the gear installation first cut the borders of the gear cutouts along the line and clean
the edges. The cut out parts will not be needed anymore, so you can cut slightly smaller and sand to
fit. Please note the cutting line Gear doors and permanent mounting covers have to be cut from the
laminated carbon fibre part . Fit the 2 permanent covers in tightly, and make sure that around each
gear door’s edges is a nice and constant gap of approx. 1 mm all around.
Now use a jig saw blade to remove the center area plywood from the gear mount. When we build
the internal structure of the Corsair wing, we have to make sure that the two gear ribs are in the
absolutely correct alignment and position, so that the wheel will fit nicely into the wing. And it’s
tight back there. So we square the mounts by leaving the gear mounting rails and the center wood
connected by a few tabs. It is a few minutes work to cut this part out. Be careful not to damage the
top wing skin with the jig saw blade. After the center wood is cut out and removed, you’re the first
person in the world to see the wood structure beneath, so if there is need to re-glue a glue joint,
now will be the time to do so. Clean the wood edges with sand paper, where necessary.
Important: After cutting the wood please
check all glue joints which appear below.
Use epoxy glue and, if needed, some little
patches of fiberglass reinforcement.
Cut the opening for gear
doors and permanent covers
in the center wing and also
cut the gear doors an per-
manent covers from the
carbon parts. See the lines
on the photos!
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