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Center
spar section made in two days with help from Steve Rahm during an assist
visit. It turned out beautifully.
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Pultruded carbon
rods for the caps. |
Here's how the ends were finished off.
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Center section with
phenolic embedded and sandwiched between lay-ups.
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Right main spar inner bid
and caps in. It still needs to be filled and phenolic attachments
added and out BID. |
Left spar completed, both
filled and wrapped. |
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Ribs being bonded to main spar. |
Rear spar fitted. |
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Used backless SFT's, no duct tape, instead used peel-ply on the side under
the foam. The aluminum tape was used to keep the glass from sagging
on the underside. |
Resulting flanges |
Here's a new method of putting on
one side of the skins I picked up from Steve Rahm. Using a straight edge
to hold up the skins, then tacking then in place with CA. |
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The clamped straight stock gets an
1/8" spacer (two popsicle sticks) to drop the panel past the ribs - for
sanding flush later. |
Cut the holes for the aileron push
tube. |
Cut phenolic plates and fitted and prepared for landing gear attachment. |
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Left stub wing, flanges for
closing. |
Radiator in place with plumbing. |
Aileron push tube routing. |
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Access hole for radiator
plumbing. |
Push tube through landing gear support.. |
Aileron idler at end of stub wing. Will get a support block soon. |
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Outer rib of stub wing. |
Wing root. |
Idler support. |
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Stub wing about done, about ready
for top skins and access panels. I used 1/2" plastic tubing as a
housing to run the brake lines in case they ever need to be replaced. |
Here's where the 1/2" tubing exits
near the gear leg. |
Spar leveled, triple check and drilled. |
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Rib on spar. |
Ribs marked with popsicle marking jig. |
To keep tension on the lacing cord, I had help from my 2x4 friend. |
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Leading edge ribs shaped. |
Left wing ribs shaped. |
Here's an alternate way to attach the bottom skins without making the
flanges first. Saves a little time and weight |
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Using a long straight edge with 1/8" thick spacers, hold he skins in
place, the tack with CA glue. |
Move the straight edge along and
keep tacking on the top side. |
Leave them hang so they can be
trimmed, then individually hold them up and tack with CA for the remaining
5 inches. |
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Skins trimmed, scuffed and prepped
for BID |
BID placed in each box. |
Underside before sanding. |
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Attached aft ribs |
Then skins with CA using a long straight edge as a guide. |
Not bad. |
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View of root wing box. |
Skins trimmed and rear spar tacked in place. |
Leading edge foamed. |
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Flipped wing. Approximate weight was 30-40lbs at this point. |
Mark guide ribs at 10 percent
increments. |
Used a long sanding board and
followed matching increment on root and outboard rib. |
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More sanding, rounded over all
sharp edges. |
Rear spar attachment. |
Spar dug out, prepped for glassing.
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This was a low spot
on a panel. I encircle it with aluminum tape, then used two-part urethane
foam with some 4 mil plastic to pat it down. It worked well.
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Left wing sand, ribs cores
dug out, and spar cleaned up to be glassed. |
Leading edge joggle. |
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Left wing glassed. Drilled small
holes on level line where pins (finish nails) were used to support a
straight edge. Then a SmartTool level was used to level both ends during
the cure. |
Left wing re-installed. |
Right wing leading edge foamed
and sanded. |
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Right wing sanded, rib cores dug out and spar cleaned up. |
Right wing micro'd and glassed. |
Shows where glass intersections
cross at spar. |
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Leading edges trimmed. |
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Ribs marked and scuffed for flanges. |
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Use a Laser level to mark the
aileron tube placement. |
Holes cut. |
Actually checked with a string. |