.
m. Carve and sand the trailing edges round. Carefully block sand the entire wing until all joints are smooth and even. Use as
large a block as possible to avoid sanding down anyone area too much.
13.
Cutting Out The Ailerons
a.
Locate the 1/4" sq. balsa Bottom Spar under the Top and Bottom Aileron Sheeting. Draw guidelines on both sheets about
1/32" behind the spar. Use a straight edge and a sharp knife to cut through the Aileron Sheeting along the guidelines. Make
sure you are not cutting into the spar.
b.
Take an X-Acto razor saw and pry the crimped metal backing off of the blade with a screwdriver. Insert the saw blade into
the slits just cut in the Aileron Sheeting and saw through each of the ribs of the aileron.
c.
Saw through the trailing edge and carefully remove the aileron.
d.
Trim and sand the back of the wing cutout until all ribs and planking are flush with the back of the balsa spar.
e.
Trim the aileron front in line with the rib angled die-cut slits. Use a sanding block to straighten the aileron front and ends.
f.
Glue 1/4"x1-1/2" balsa into the wing cutout and to the front of the aileron. Trim and sand these pieces to wing contour.
g.
With a razor saw, cut the base off one of the long nylon control horns that are supplied. Drill some random glue anchor
holes in the top area of the horn.
h.
Inlet the bottom leading edge of the aileron to allow the nylon horn to be slid in place alongside the plywood riblet W5A.
Refer to the aileron cross-section drawing to see how far in the horn should be installed. Hold the horn in position and drill a
small pilot hole (for a #2x3/8" sheet metal screw) through one of the glue anchor holes and into the ply rib. Screw and epoxy
the horn securely in place.
i.
Fill in behind the horn, on the bottom of the aileron, with 3/32" sheet balsa. Sand flush. This will give you somewhere to
attach the covering material. If you wish to cover the ailerons before hinging, do it now.
j.
Cut slots in the aileron leading edge and the wing cutout to accept the nylon hinges. Use 4 hinges per aileronl Check the fit
and movement of the aileron by dry fitting it into the wing first without any glue on the hinges. If there is any mismatch or
binding, alter the slots as necessary to correct. Epoxy the hinges in. Repeat these steps to complete the other aileron.
14.
Mating The Wing To The Fuselage
a.
Epoxy the 3/8"x1-1/2"x5-3/8" basswood Wing Bolt Block in place. Brace it to the lite-ply Cabin Bulkhead with 1" triangular
balsa. Let dry.
