40% Extra 260: Own-design build thread

[dmichael]

Next, I drew up and cut out the turtledeck formers. Formers laid in place and stringers glued to formers. Note that the turtledeck formers are held back from the fuselage sides by the thickness of the turtledeck- 3/32" on both sides.

[dmichael]

More shots of the turtledeck.

[dmichael]

Sheet the turtledeck with 3/32 balsa.

[dmichael]

Here's a shot into the fuse that shows some of the reinforcments added.

[dmichael]

Here's another shot of the fuse.

[dmichael]

Hatch is next. Not sure why but this is the only hatch shot I could find.

[atique]

Wow! That looks great

[dmichael]

Next I did the stabs.

First shot is of one of the foam stabs we cut. Since it is relatively small, it's not that difficult to do. I have some of the markings laid out for the hinge line and the phenolic and have the hole cut at the end of where the phenolic will be so that we can get the end of the cutting bow in to cut the phenolic hole.

[dmichael]

Next I lay in the templates for cutting the phenolic hole. I used a piece of counter-top material for the templates and laid them in place on both ends using small nails through holes that have been drilled into the templates.

I used bricks to weigh the stab down while I ran the wires to cut the foam. I found that this is a one man operation- using both hands to drop the wire down through the surface of the foam, around the hole and back out again. This wasn't all that hard to do.

[dmichael]

Here's what the hole looks like after cutting.

[dmichael]

Phenolic is installed with pro-bond and a plywood plate is constructed and sanded to fit the contour of the airfoil then installed at the end of the tube.

[dmichael]

Next, I used a dremel tool with a router attachment to make some cuts into the foam for the servo rails and servo pockets.

I elected to install additional reinforcement for the anti-rotation tube so that it would be supported on both ends. Using the bandsaw, I cut into the stabs, top to bottom, so that I could insert a small rib. The rib has a hole in it that accepts the end of the anti-rotation tube and is cut/sanded to match the contour of the stab airfoil. As you can see, I haven't finishes sanding this small rib as it sticks out a bit at the leading edge.