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Old 02-23-2012, 06:54 PM
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Good stuff Terry!!
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Old 02-23-2012, 08:45 PM
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OK, made a couple of hours tonight to get a workout with the sanding block! Lesson number ONE, trim the sheeting closer to the size of the foam!!!

I got the leading edges, trailing edge and caps all sanded flush and the root edges of the stabs fit tightly onto the fuse sides. I still need to sand / final fit the wing roots to the fuse sides, will get that done tomorrow afternoon and maybe get some LE and TE stock glued on.

(The other set of wings and stabs is for my Aerotech Edge build......yes it's still in progress).
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Old 02-23-2012, 09:13 PM
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Holy crap you even made your own sanding block!
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Old 02-23-2012, 09:25 PM
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you got alotta sanding to do boy! have fun with that eh! lol! i like building the fuses as they build quick and look good, but foam wings is all sanding! You sanding the sheets BEFORE you skinned the foam, didn't ya?
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Old 02-23-2012, 09:45 PM
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Originally Posted by Bam Bam View Post
you got alotta sanding to do boy! have fun with that eh! lol! i like building the fuses as they build quick and look good, but foam wings is all sanding! You sanding the sheets BEFORE you skinned the foam, didn't ya?
I got them close before gluing, but the place I got the sheeting from has some thickness issues I think. There were sheets that were +/- .018 which does not sound like much, but it's a heck of a lip at basically 25% of the thickness of the sheets. I ordered wood for my next build from a different place that actually had 10.5" x 48" sheets pre-glued. Less glue joints and sanding That's on order with some lite ply that I need, so that should show up soon.
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Old 02-23-2012, 09:49 PM
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Originally Posted by lakerider8 View Post
Holy crap you even made your own sanding block!
That was a quick put-together tonight, I think I'm going to CNC one with a better handle and perhaps a removable side plate that can ride on the table top to sand perfectly at 90 degrees for the edges.....still need some more thinking on that design.
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Old 02-23-2012, 10:08 PM
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Originally Posted by terryscustom View Post
OK, made a couple of hours tonight to get a workout with the sanding block! Lesson number ONE, trim the sheeting closer to the size of the foam!!!.


I love seeing all of that weight savings on the floor! Nice job.
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Old 02-25-2012, 10:23 PM
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SOMEBODY did not order enough 1/2" balsa for the LE and TE's of my wings. Soooo.... I sanded the wings roots to fit on both planes and everything lined up great But, now the Aerotech wings and parts are back on the "to be continued" rack for a couple of weeks.

I went ahead with gluing the LE and TE's on the scratch build wings and stabs. Finally sanded up my rudder so that's ready to work on more tomorrow. Lasered out and installed a vented plate for the cans to exit. I also lasered out a couple of templates to route out holes for the servo boxes and the blocks that the G10 horns will be installed into.

The Aerotech elevators don't leave hardly any room for servos.....the tube really should have been moved somewhat. If the servo is in front of the tube the stab is too thin, and if the servo is in back of the tube it needs to sit sideways. So, I guess it will sit sideways..... While designing my Extra I moved the tube back so that the servo would be just in front of it and still use a 3" pushrod.

My wife did not have much going on so she assembled my servo boxes for me She does good work and they are all perfectly square!! The servo boxes only weigh in at .19oz each so they are pretty light.
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Last edited by terryscustom; 02-25-2012 at 10:51 PM.
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Old 02-26-2012, 09:46 AM
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Looking great, Terry. I would have to go and help clean the house, to get my fiance out in the shop to help me out.

You've got a keeper.
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Old 02-26-2012, 06:37 PM
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Lots of work today, although it does not look like it. Sanded the LE and TE as well as the rest of the wing surfaces. Glued and sanded wing tips and other caps. I also got the hard-points glued in and drying for the night. I wanted to get the servo boxes glued in to, but I have to call it a night. Will work on those tomorrow night.
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Old 02-26-2012, 06:39 PM
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Sometimes tons of work doesn't look like much! That's how my day went too.
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Old 02-26-2012, 06:42 PM
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Those pics don't do it justice. Stopped by today and everything is looking very nice.
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Old 02-28-2012, 10:35 PM
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OK, got done with work at a semi-reasonable time today so I spent some time marking out the ailerons and elevators so I can cut them out soon. I also cut out all of the servo bays in the wings and stabs and got the boxes trimmed and glued in for the night. Forgot the camera so you'll have to use your imagination for today

Now, question for the pro's (and any more experience than I).......When cutting out "notched" counterbalances, what is the best way to do this. I have seen some cut them out with a knife (and a bunch of patience) and I've seen many that just cut them off and glue them back on with some poly glue and some dowels or CF rods. I've been leaning toward cutting them off and gluing them back on.

The notched counterbalances are shown on the ailerons on this pic:
http://www.flyinggiants.com/forums/a...8&d=1327374233
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Old 02-29-2012, 02:59 AM
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I cut mine out as close to how they will be when complete for no reason other than its one less potential join line that can show up after covering, not really important cuz there is still edge lining to do on them. Any way is fine since they are smaller than stab balances and mostly there for show.

Sometimes I like to add a large soft block LE section to the CB so I can hollow it out and pack it with lead but thats only on designs where the balance is large and the aileron is 'heavy'. I only do it because I'm fussy on making things right for my own satisfaction.
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Old 02-29-2012, 10:46 AM
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Here's a couple of pics with the boxes installed. They fit absolutely perfect and should work great. Also made a sample block for the G10 horns to hook into. Going to cut those holes and get them installed later today, as well as (with any luck) get my wing roots glued on today as well.
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