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Lots of Cleaning of the Spray Equip. Lots of MEK! |
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Step 1, Ribs and flase Ribs |
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Lots of clamps were used....LOTS! |
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First coat of Color Poly Tone |
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Day One! Unpack the box of wood and plans |
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WIng tip bow, made from laminates |
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Leading edge made from 1/16" plywood wet formed and tac stapled & glued in place |
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David Jr. stenciling the scallop pattern to cut out |
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Starting to build the Alerons from the cut out wing section |
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2.9 Gal wing tanks, one in each upper wing |
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Fitting Aleron torque tube |
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Wing walk for front cockpit entrance |
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"N" strut fitting. Make sure you install these BEFORE you build the wing!! I did not and the drilling of the holes was very difficult! |
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T88 sands very nicely and leaves a professional result |
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Building wing root fairing for a smooth look after the fabric is installed |
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I made this wing root pocket for a nice finished look. The plans just have the root pressing up against the fabric |
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Alerons after 2 coats of 2 part Poly Fiber Varnish |
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Doug and Justine Varnishing....great helpers!! |
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I covered the alerons first to get the hang of it |
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What could be better...Great memories were made on this project |
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Calibrating the Iron…VERY important! |
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The entire covering process was fun, fulfilling, and very rewarding. |
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I recommend attending a Poly Fiber weekend seminar so you feel comfortable with the entire process. |
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Wing after taping and 1 coat of Poly Brush, brushed on. |
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Lots of care must be taking in wet sanding, even with 400 |
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I did 3 cross coats of Poly Silver, overkill! I should have stopped at 2 |
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After two spray coats of Poly Brush now ready for Poly Spray |
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Ribstiching...Yes it is tedious, but it must be done. First wing took 8 hrs, each wing after that was much less. |
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Jig for rigging the wings, setting angle of incidence, dihedral, and setting all wires.
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This step takes a lot of time and careful planning, you got to get this right!!! |
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I set 3.5 Deg upper and 2.5 Deg lower AOI on the wings. I wish I set 4.5 & 3.5 as the nose is just a bit high in level flight. |
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Wing rigging, I set 1 deg extra AOI on the top wing and I find the stall is just perfect, glad I did |
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I used a laser level and a digital smart level to make this tough job easier |
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I made a spray both out of PVC pipe and plastic sheets. It work great |
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