Topsoaring New Technology Co., LTD
Top Sky DLG Install Guide
TopskyInstallGuide-(English version).doc
Page 35 of 40
Glue it in place
Starting the pushrod exit holes
Filing them out with the rat tail
Time for the wing! The wing root is pre-beveled for a 6" dihedral, so that saved A LOT of time normally
spent sanding in the angle. Also, this wing uses balsa at the root and carbon sleeves down where the
wing bolts go in, so no hard points are needed, also saving time.
Marcus decided to use HS-45's for the ailerons, so first thing to do was make a template. Using some
thin cardboard from a servo box, we made a template to match the outline of the 45's. Following the
directions, the servos were to be placed in front of the carbon spar. Then also using another plane of
mine for reference, we decided to place the horns on the ailerons in 30mm from where they're cut out of
the wing. Marking 30mm in, I used a square against the hinge line and placed the servo template on the
wing.
After taking some careful measurements of the template on the wing so that servos would be even, it
was time to cut! Exacto made quick work of the glass, and then the foam left over was dug out with a
scratch awl. And the fit? Like a glove! The 45's fell perfectly into place. Then I used a hole-saw made
out of brass tubing to make a wiring channel.
Next it was time to mark the bolt holes through the wing. The best way I've found to do this with the
balsa root wings is to line the wing up on the pod, mark the holes with a pencil, and then use a rat tail file
to file out a channel through the root. This eliminates the "is it square?" guess work when drilling the
wings after they've been joined. Plus, this creates a pilot hole so that all is needed is to enlarge the holes
to fit the bolts. Also the wire channel was marked and filed out. After the balsa was filed, Marcus took
an Exacto and added a few pin holes in it to give the epoxy in the root a better bite. Then it was time to
tape off the roots and sand the skin so the wing-root glass would have good bite.
Once all the ground work was done, it was time to join the halves. Since this wing relies heavily on the
strength of the glass and carbon patches to hold the halves together, only a small amount of 5 minute
epoxy and micro-balloon mix was used to join the halves. The epoxy was set in and the dihedral was set
