Building Sequence
If this is your first AirCore plane, we recommend you build the COLT 40 over a period of 3-4 evenings or a couple of days.
Your future AirCore planes will take less time, but we feel it's important to take your time on this first one and do it right.
The first evening we will prepare a few parts with glue and epoxy, and get to know the plane. The second evening we will
build the fuselage and tail feathers. The third evening we will construct the wing. The fourth evening we will assemble the
Power Cartridge and check alignment. Next weekend we fly!
EVENING ONE
NOTE - "LEFT" VS. "RIGHT' in this manual. When we refer to the "left" side of the fuselage or the "right" wing in this manual,
pretend you are the pilot of the plane, sitting in the cockpit, facing forward (toward the engine). The "right" wing is the wing
to your right. The "left" side of the fuselage is on your left, etc.
This is "getting to know you" night. We'll build and prepare only a few things, read the manual, do some thinking about what
our final plane will look like and be ready to do some serious building tomorrow night.
BEFORE YOU BEGIN, READ THIS MANUAL FRONT TO BACK, THEN COMMENCE AS FOLLOWS
BE CAREFUL WHEN REMOVING PARTS FROM THE TRIM - DO NOT TRY TO "PUNCH" THEM OUT - USE A HOBBY KNIFE AND CAREFULLY TRIM
THEM FROM THEIR PROTECTIVE SURROUNDINGS OR THEY WILL TEAR.
1.1 Remove all of the parts from the box and identify them by comparing them against the parts list and diagram at
the back of this manual. Carefully remove the AirCore parts from their trim using a hobby knife. Mark them with a ball-point
pen on the inside of each piece (i.e.- "right wing, inside").
Notice that AirCore parts are different thicknesses. The
thinnest material supplied is two (2) millimeters (mil) thick,
the medium thickness is four (4) mil, and the thickest
AirCore supplied is six (6) mil thick. We will refer to "2-mil"
AirCore and "4-mil", etc., throughout this manual, so
acquaint yourself with the different thicknesses now.
Terms you will need to know when working with AirCore,
include the word "flute" and "score." Observe a piece of
AirCore from the end and notice the "holes." We call these
holes "flutes." Flutes run the length of each piece of
AirCore, parallel to each other, and give the material its
"grain" and strength. Scores are pressed into the AirCore
where we intend for you to bend it. Note that the scores are
on one side only of the pieces - this is the inside of the
piece that the score is on. When marking exterior AirCore
parts, always mark the inside of the piece.
THICKNESS (IN MILLIMETERS)
2-MIL
4-MIL
6-MIL
FLUTE WALL
FIGURE 1 - GETTING TO KNOW AIRCORE
1.2 "Experiment" a little with the fuselage and the wing, fold them up some and imagine what they will look like
when complete.
IMPORTANT:
WHEN FOLDING THE AIRCORE PARTS, DO SO ON A FLAT SURFACE AND USE A GOOD YARDSTICK, STEEL RULER OR CARPENTER'S SQUARE
AGAINST THE SCORES WHEN MAKING THE FIRST "BREAK" ON A SCORE - ESPECIALLY WHEN BENDING THE SCORES AT THE LEADING EDGE OF
THE WINGS. BREAK-IN ONE SCORE AT A TIME THE FULL WIDTH OF THE LEADING EDGE BEFORE STARTING THE NEXT, ADJACENT SCORE. TO
ASSIST YOU IN WORKING THESE SCORES, TRY WARMING THEM FIRST WITH A HAIR DRYER. USE THE BACK OF A POCKET COMB WITH A
STRAIGHT EDGE, IF NECESSARY, TO CREASE A TOUGH SCORE BEFORE BENDING IT.
Be careful when handling the AirCore material so as not to "crease" it in an area not meant to be bent.
Now let's build some preliminary parts so tomorrow night and others will go quicker.
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