Aerotech 42% - Twin Build

[Fixed Wing]

1st picture shows weight on vertical stabs after being sheeted. 2nd picture shows hatch tops, turtle decks, belly pans, and fuses after sheeting has been glued, trimmed, and sanded. Vertical stabs have not been cut into fin & rudder portions yet and are just standing near the rear of the fuses on the table.

[sweetpea]

Looking great....you might just get done for next years competition

[Fixed Wing]

I Hope to have one of these ready to fly by the end of next month. These newer planes have a bit thinner wing than the original one I'm current flying (which I really like). So I'm a bit eager to get one in the air and try it out.

[Fixed Wing]

Sanding is required to prepare the wing and stab foam core roots to fit flush with the fuse sides. I found it is easier to mount the large flat sanding block upside down against the table and work the cores on it rather than vice versa.

[Fixed Wing]

These pictures show glue entry holes being cut so the phenolic tubes can be glued into the foam cores. Glue is poured into the hole as the phenolic is slowly rotated and pushed into the core. This ensures that a nice even coat of glue gets all over the phenolic but prevents glue getting around either end so as not to impede smooth sliding of the actual wing tube through the entire socket.

[Fixed Wing]

These pictures show weights placed on the foam cores while the glue for the phenolic tubes dry. Not much weight is required for this. Just enough so that things stay in place and the slit in the top of the cores don’t try to spread. Its hard to notice but the wing tube is placed into the sockets of both the left and right stabs as they are drying to ensure they are exactly aligned. Much more weight will be used when the wings are skinned.

[Fixed Wing]

This picture shows how I did the sub rib inside the main wing at the end of the phenolic socket. This could be over kill and may not be required but I did it anyway for peace of mind. Notice that the phenolic socket actually goes through the sub rib and is glued in place. I once had an ARF whose wing socket crushed the foam around it inside the wing and the wing became loose and spongy when mounted. When I cut into the wing to fix the problem I found that the phenolic socket was just butt glued with a broken joint to the sub rib and the wing tube wasn’t going through it. The method in the picture ensures the wing tube actually goes through the sub rib and spreads the load better within the wing. The end cap is thin ply glued to some standoffs to create stops for the wing tube. When both wings are mounted and in place the wing tube has about 1/16th inch play side to side before hitting the ply stops. Again, this whole issue may not be a concern but I addressed it just in case.

[Fixed Wing]

The first picture shows the weights used on one of the stabs after they were skinned. The 2nd picture shows all the sheeted pieces after they were trimmed and sanded. The only things left to skin now are the main wings. Hopefully, those will be done next week. The last picture shows the various foam shucks. I have foam pieces everywhere!

[Fixed Wing]

This picture shows a paper template which will be used to mark various aspects on either the wing cores or the skinned wings in order to complete them.

[Fixed Wing]

These pictures show how I cut the channels in the wing and stab cores to run the servo wires through. The pictures should be self explanatory. My buddy Kevin talked me into doing it this way and it was very simple and accurate to do. Thanks, Kevin. I thought the little foam worms that came out were kind of neat.

[Fixed Wing]

First of four wings being sheeted. I hope to do one each day throughout this week. The concrete blocks total to about 400 pounds.

[Redneck Shaun]

Great job Dean. Looks like they are coming along very nicely.........I wish I had the patience to build.
Shaun