Page 6
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Construction Manual
Step 25 - Wing Assembly (cutting R1 & R2)
Carefully cut away the center of the R1
and R2 ribs, leaving a box as shown
in the photo. Carefully sand the inside
of the box so the edges are smooth
and flush. This forms three sides of the
dihedral box and needs to be smooth
and free from edges so the dihedral
braces will slide in smoothly when
joining the wing halves later.
Step 26 - Wing Assembly (cut upper spar)
Lightly sand the edges of the bottom
face of the spar as shown in the drawing
to the right. This will help the spar slide
in easier.
This next part takes a bit of time, so we
recommend against using an instant
setting glue. If you
are using CA, use a
thicker formulation
that gives you a bit
of working time.
Locate the extra
length of 3/16” x
3/8” basswood strip
you marked as the
upper spar.
Apply glue to the top of the ribs where they will contact this spar.
Working from the tip rib (R6), carefully press the upper spar into
position. This will be a tight fit and might require “wiggling” the
spar from side to side to slip in-between the sheer webs. Be sure to
press the spar completely into the slot in each rib, making it flush
with the sheer webs.
Now wick thin C/A along the spar to sheer web joints (front and
back) along the entire length of the spar
When fitting the upper spar to make the top of the dihedral box,
be careful not to drip excess glue into the box formed between
R2 and R1.
Step 27 - Wing Assembly (leading edge sheeting)
Locate the remainder of
the 1/16” x 4” x 24” sheet
you trimmed back on step
21. This will be used as the
upper leading edge sheeting.
Measure and cut to length.
Rather than attempting to
wrap and install this entire
piece at one time, glue the
leading edge sheeting in
place as shown here.
To aid in making sure the
entire length is properly
held in place, use the same
straight-edge from back in
step 20 to push down along
the entire edge of sheeting until the glue has cured.
Step 28 - Wing Assembly (leading edge sheeting)
Once the glue has cured from the
previous step, then you can carefully
start to wrap the leading edge sheeting
to the ribs. Make sure that the sheeting
is glued to the surface of each rib, the
front sub-spar and the top main spar.
Sometimes it helps to add a few
weights to the rear of the wing to hold
in place while bending the sheeting.
Step 29 - Wing Assembly (center sheeting)
The ends of BP18 and
BP19 have extra 1/16”
sheeting that are used for
this step. Measure and cut
a few pieces to form the
center sheeting between
the R1 and R2 ribs. The
sheeting should be flush
with the R1 rib, but overlap
R2 by a 1/16” or so. Note the grain direction also. You’ll have to
piece this together from a couple of pieces and take your time to
ensure a proper fit.
When satisfied with the fit, glue pieces in place as shown.
Step 30 - Wing Assembly (cap strips)
Many of the 1/16” laser
cut sheets have 1/4”
wide cap stripping pre-
cut into them. Use a few
lengths of this to make
the cap strips for the top
of the wing.
Cap strips are centered
over each of the R2-
R5 ribs. The cap strip is flush with the edge of the R6 rib, resting
against the T1 and T2 pieces already glued as part of the wing tip
assembly.
Each cap strip runs from the back of the leading edge sheeting to
the front edge of the trailing edge sheeting.
Step 31 - Wing Assembly (aileron top sheeting)
Locate one AS from
BP19. This is the top
aileron sheeting.
Note the position as the
shorter cutout is located
in between the R4 ribs
and towards the rear of
the wing.
When satisfied with the positioning, glue it in place, making sure it
is glued to each of the R4, R5 and R6 ribs and to the leading edge
of the aileron.
Step 32 - Wing Assembly (rear wing sheeting)
Locate one TS from BP19. This is the sheeting for the back edge of
the wing. Glue it in place on the back of each of the R1, R2 and R3
ribs, as well as the trailing edge of the wing.
Lightly
sand here.
Lightly
sand here.
