Making Composite Plane – Preparing the Wing Cores #2

all right far2 back in my basement not on the garage anymore it’s a mess you can tell but tonight we’ll prepare the course for the skins there’s probably many different ways to do this as there are to do anything else and there’s probably no right way or wrong way there’s just different ways to do it this is the way I do it pretty much everything that I do or know about laying up wings is I learned from Phil Barnes video so if you want more information or you want to have a good video yeah check into that that’s a really good video to teach you how to lay up all sorts of wings and prepare the course and kind of kind of what I’m showing here but a little bit more depth in detail so first thing you do first thing I do that’s the plan form it’ll have rounded tips we’ll get to that a little bit later um first thing I do is is all sand I’ll sand the cores a little bit to get the fuzz off change the shape that I’m not really all too careful with this stuff either a lot of fuzz you see this on the cores themselves kind of got to be careful when you sand them you don’t get this stuff that balls up on the sandpaper in their leaves divots in the colon of course I like to stand my course to get rid of all this fuzz I don’t really want to don’t want to change the airfoil at all I don’t really want to sand into the wing you just kind of want to take off the shininess where the wire cut just kind of sand down to to make it kind of dull and that’s really all we want to make sure that the trailing edge is zero thickness you know this one is pretty much a zero thickness already but you want to sand that out make sure it is so I tend to stand from about the high point back to the training edge never sand this way because you’re going to roll up the trailing edge to do that just go through and do it so probably a lot of fast-forwarding through this video because this there’s not a whole lot to see and you don’t really want to watch me saying you want to sand any wire ridges off – you know sometimes the wire will skip a little bit you’ll get a little bit of a ridge and see one right there but I can’t feel it with my hands at all but I still like to sand that on the leading edge ice and just a little I always sand towards the end so if I’m going that way or this way I just kind of stand it down I really want to do a whole lot of sanding on the leading edge you don’t really need to just kind of want to remove the fuzz that’s left from the hot wire okay so that’s pretty much it on that side know I always transfer the wing from shuk – shuk the core just moves from back and forth so then that leaves this this side and sandals it probably not really that important to sand that the the outside chucks I just like to do it just make

sure I keep that the Swiss burgers from getting back on the floor after I put it back together Tiger no where’d he go interruptions are often at this house so then same thing on the bottom of the wing be careful not apply too much pressure this is just a sanding block I put together sandpaper glued to its plywood and then a piece of bolts are glued to the plywood to make it a little bit softer and then piece of sandpaper the same thing with this one hopefully in like eight times speed or something you okay now the cores are pretty close to being ready what I do next is I’ll cut out the I’ll cut to get the tips and my template for this I just learn the temp little edge trim edge grab a pan trace the outline okay so you can see the outline of this wing tip is traced on through the core then I will take man that stuff makes you itch razor blade and follow the line the end of the wing don’t need so there’s the leading edge of the wing that looks good except look how fat that is so much badder than the rest of me so we sand that down what I do I will freehand one I still want I still want the wingtip to be at the center of the wing so I just mark a dot eyeballed right in this equidistant you know right in the middle of the wing and where I cut the daughter was sick you see that so like that and then I notice and to the dots top and bottom so that the wing comes together evenly looks like it’s banned breakfast I think we’re gonna have to do this later reluctantly crouched at the starting line engines pumping and dumping in time

the green light flashes and the lights go up Charlie and Bernie in your lap all right band practice is over for tonight it’s just about my bedtime so I might sand this wing down a little bit but I’m sure that you can see what I did on that little dots room and I just kind of feather it back from a little bout right here out to the tip so it’s not really a sharp transition to kind of portraits right down you okay it starts to get thin then I kind of really bullnose the end over but you kind of make it like this leading edge try to make it the same shape and parabolic a little bit so they blend in together just a little bit of cleaning up on the edge really lightly okay now look at that if you can see it but it’s a much better leading edge feathers – nice and left one wing half the other one is darling is exactly the same you now the ends are the tips are down I mean now we glue glue the core together I glue it with super 77

okay need to get glued together I’m gonna have to do it like this exactly obviously block it around but see not that much okay it’s important that you get these two sides even top and bottom left and right hater my bracelet course I’d open up there the next thing we do though let’s place on the bottom of the wing this is I’ll come to take that Ridge out a little bit a little bit of sanding it doesn’t take much just glue it together right now going to my template get two and a quarter inches down let’s draw straws for the servos that sit out in the wing for the ailerons so after the wings belt you can punch a hole in the in the skin right here hit the straw run the wire out cut you’re cut out for your servo and then you got a channel to run here servo wires and this is two and a quarter it’s a straight leading edge this wing so like a major two and a quarter out here too otherwise you have taken your penalty well folks looks like I ran out of memory on my memory card so you missed me cutting out the trench for the straw I use a dremel in this bit right here won’t focus very well will it anyway I just make sure that I just freehand the cut make sure that it the straw sits below the level of the skin of the foam so it doesn’t sit proud and then I glued it down with a little bit of foam safe CA so that it will stay put while I push chiller in and that’s really the only thing that’s left do tonight I’ll go ahead and do that alright filler I use is this stuff right here fast and final lightweight spackle it’s really light almost like air

spreads pretty easy use edit there it is use a credit card to do that best thing best use for the wipes credit card spread and spackle and I just scoop some up fill the hole almost out okay now that it’s wet and it’s heat it’s pretty pretty even with the top of the foam but it’s going to shrink for sure when it dries so what I’ll do is I’ll add a little extra on top so when it shrinks extra to build on gonna probably take another coat anyways I like this to be flush is possible with the bottom of the Queen and even this one there will still be some perks that are lower so we’ll take one final quick add additional amount I’m going to kind of sand it a little bit more well done anyway so it’s not that important the log gets picked up but it’s really easy to pick it up at this point the stuff that’s outside the draw and that is where we’ll end tonight I’ll let that set up tomorrow we’ll sand it add one more finished coat then we’ll be ready to lay the wing up although I’m waiting on fiberglass to show up I used up the last fiberglass last week so the aircraft should have a shipment in the mail on Wednesday so I won’t be able to lay it up tomorrow but hopefully Wednesday all right that’s it for now