Tag Archives: Building

Building Aero 3D Day 53: Wing Bolt Holes

Wing Bolt Holes Top

Wednesday, made some more progress on getting the wing bolting system in place.

First thing was to get the hole locations marked on the wing hold down plate (FUE). Since I already had the holes drilled into the wing I used the 1/4” bit to place through the holes, while the wing was held in place on the fuselage with clamps, to make markings on the  hold down plate (FUE). Next, I put the fuselage, with some support, on the drill press and made sure the plate (FUE) was perpendicular to the drill bit (size 5/16“) and drilled the holes.

Once the holes were drilled I filled the T-Nutts with vaseline to ensure no glue got inside and mixed up some 30 minute epoxy, which I applied all along the buttom of the nutt and up the shaft before pushing it (from the bottom) into the previously drilled holes. Used a C-clamp to squeeze the nutt into place. Checking and adjusting the clamp as we went. You can see the result in the featuerd image (top view) and right imge below (bottom view).

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Building Aero 3D Day 51: Bolt Holes & WF Assembly

Bolt Holes Drilled

Yesterday afternoon I made minor progress on the aircraft. I started by continuing with work on the wing. I marked the center between the outter and inner WDs on the previously marked line indicating where the wing lines up on the center of the ply wing bolt plate in the fuselage.

I also cut 1/4” x 1/4” balsa stringer, FU-ST-2 to a length of 23 5/8“, to see how it would fit into the bottom of the fuselage and into FU6B… it isn’t perfect but workable once we touch up FU6B, the angled ply piece I put in with the WD assembly since their angles need to match up. I didn’t glue this piece into place yet as the other tasks still required on the fuselage will be easier with the spaces open.

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Building Aero 3D Day 50: WC Assembly

WC Assembly Side 1

On Wednesday I was finally able to make some more progress on my wing. What was the hold up you ask? Well, I needed to make the WC assembly and the types of pieces and angles involved I couldn’t seem to get it done on my own. After telling a co-worker about it (Catherine) she graciously helped me with assembly.

I brought the pieces to work and after our work day was done she became my extra set of hands and between the two of us, one holding and one gluing, we were able to get the WC assembly built… not perfect, but done. Medium CA was used, applied to the joints get the balsa pieces, two outer WE’s and three inner (bigger) WD’s, attached to the WC ply plate. Seen in the left pic below.

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Building Aero 3D Day 49: Aileron Hinge Supports & Awkward WF Contemplation

Hinge Supports Glued onto Ailerons

Yesterday, I cut eight pieces out of 1/4“x1/4” balsa stringers to a length of 11/4“. I then marked the center of them and glued them to the inside leading edge of the ailerons, using wood glue, and clamped them in place. The purpose of this is to provide more support/substance for the hinges. I used weights to ensure the ailerons stayed flat on the surface and clamps to keep the balsa pieces tight while the glue dried. You can see the result in the image above.

Next, I attempted to make the assembly for the bottom back of the wing… I’ll call it the WC assembly. Everything I tried to keep things in place just wouldn’t work, from doing it on the workbench to overtop of a piece of wax paper on the wing itself. I even sanded the angle into the WC edge a bit to see if that would help but due to the awkward way the WC angles below the WDs & WEs when the pieces are flush and needing to be to be to the ‘bottom’, which is what I’m calling the longer side, when upside down I just can’t get everything to come together. I think an attempt at using CA is in order… it is so fast acting you basically get one shot before it sets at getting the piece in place properly.

That is where I’m at. The other thing I can do is sand the front WF assembly so that the WGs are flush with the top of WF as then I can put the balsa sheet (W-SH-7) over top.

Building Aero 3D Day 48: Wing Fitting & WF Assembly (Again)

Wing Filled and WF and WGs Glued

Yesterday, Peter dropped off my wing and did a trial fitting into the fuselage. He graciously fixed my previous mistake where I glued the WF assembly to the wrong side of the wing, doh! He was able to remove it and repair the damage to the wing. You can see part of the sanded filler in the featured image above.

As part of the trial fitting, needing to get the wing to sit flush without pushing down, drilled out the holes at an upward angle as well as sanded the doublers. I’m concerned sanded to much before realizing the reason was the addition of the square piece on the wing to reinforce the sheeting around where the servo leads will go through.

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Building Aero 3D Day 47: Wing Tip & WF Assembly

WF and WGs Glued

Today, I put in a couple of sessions. This morning after waking up I went straight to my workshop and worked on the other wing tip. I got the WT2, WT3 & WT4 pieces (one top and one bottom) glued in place. I needed to do the supports for some of them again as they were a bit short. I don’t know if this was the best option; however, it is what I decided to do and will have to see how it all works out. I also lightly sanded the outter rib cap as where it tipped inward a bit it wasn’t flush with the sheeting at the top and leading edge.

I first marked where each piece on the top was going to go and then starting with WT2 applied glue and pinned in place, using a square to make sure they are perpendicular with WT1 (the wing tip itself). Then crouching I did the underside WT2 as well. I followed this same process for WT3 & WT4 pieces. Not wanting to disturb anything while the glue set I breaked for the morning. You can see the result in the very bottom image below.

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Building Aero 3D Day 46: Wing Tip & Wire Support

WT2-4 Support Forms Glued

Today, I worked mostly on the wing tip. I started with the right wing tip and prepped the WT2 through WT4 pieces. I started at the leading edge with WT2, making sure they fit nicely and then glued them in place, using pins each time since it is an awkward shape to clamp.

I marked on the pieces, if there was an opening, wher the edge would be, thus no glue required, followed by a pencil line for location. I then used wood glue along the bottom and side straight edges.

Using a square to ensure the pieces were perpendicular to the wing tip I then pinned the outter end of the piece into the wing tip itself and the inner end into the outter rib. I did this for top and bottom, verifying positioning with a square.

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Building Aero 3D Day 45: Wing Tips & Pictures

Wing Bottom

Yesterday, made more progress on the aircraft started by sanding the trailing edge keeping my sanding block at the same angle as the sheeting along the ribs to try and get some slipstreaming going. Though the instructions suck, I believe that is what I was suppose to do to compelete Step 5 of the Wing section.

After that I prepped the ends of the wing by trimming any excess sheeting remaining and then sanding all the sheeting flush with the outter rib. I also removed any major excess glue gobs. Yes, I know you can still see where there is glue on the ribs in the images below, but non-intrusive to the next steps. I also marked a ‘+’ in ink for all the hinge locations, centered horizontally & vertically. I then know where the center point of all the blocks I put in will be, if the pencil markings indicating the outter edges of each block fade (sample seen in bottom image).

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Building Aero 3D Day 44: Rib Caps & Sheeting Glued

Rib Caps & Mid Sheet Glued

Yesterday, after work I went straight to the workshop as I wanted to get my previously cut and sanded rib caps and W-SH-3 sheet (middle section) glued.

As typical, I used wood glue and after marking the mid-sections on any previously missed rib caps I applied glue to the top of the ribs and along the edge of the sheeting as well as the caps themselves prior to putting them in place. I then used weights where necessary to keep the sheeting down, especially on the two W-SH-5s.

In the case of the remaning outter rib cap I used a damp cloth to wet the balsa piece so that it would form to the shape of the rib better since it was of stiffer material (for some reason) and in a more precarious position since I was gluing it on the outer edge, instead of centering like the others.

Prior to gluing the middle section I added some supports, like I did for the other pieces of sheeting, both sides, providing additional support as there isn’t much to glue to otherwise. I used scrap 3/32” basla pieces and glued approx. half, using medium CA, under the pre-existing sheets. Seen in the image below.

Once that was done I switched back to wood glue, applying to the supports, edges and ribs prior to putting the sheet in place. You can see the state in which I left everything, weighted and otherwise in the featured image above.

Building Aero 3D Day 43: Trim & Rib Caps

Rib Sheeting Made

Yesterday, I made some more progress on my wing in stages throughout the day. The first session of the day was involved getting the remainder of the bottom trim glued in place. I already had the piece made so it was more about figuring out how to get everything down and in place.

I discovered that this piece actually fit better then the other side I did previously… I think this is because, though it appeared at first, the addtional block wasn’t sanded down enough, or something else was preventing the sheet from sitting down in far enough near the trailing edge. I started sanding the angle for the trailing edge to see how this was going to work, as I’m a bit concerned how that is going to turn out, but we’ll see as Peter says “There is no issue that cannot be overcome.” My issue is I thrive for perfection in an imperfect world.

I had previously marked where the sheeting came up to on the ribs so I poured out some glue and place it aong the rib edges as well as along the inside of the trailing edge. I then placed glue along the edge of the sheeting and the one end that butts up to the previous piece. Placing the sheeting I started at the but end using scrap balsa to assist in clamping the sheet tight to the trailing edge as well as over the bottom and top when clamping deown on the sheet itself. Once I had everything clamped and weighted down I added some medium CA along the butt joint to keep it aligned.

You can see the result in the image below:

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