Archimedian
Member
Howdy. What we are going to have here is a DTFB/purple foam/balsa composite build with full aluminum foil sheeting. Other features are aluminum tube for control surface hinges, aluminum tube suspension, and a belly exhaust vent.
Wingspan: 36"
Predicted weight: 400grams
The wing is built on top of a thick piece of corkboard that has been glued to a wooden board. The planform of the lower surface is cut and pinned to the work surface. I applied a wide strip of plastic tape underneath where I glued the leading and trailing edges.
A box is made on each side to house the aileron servos flush with the lower surface.
With the servo and servo wiring in place, the upper surface sheet is applied.
I attached the two wing halves before attaching the upper surface on one side. This was so i could add reinforcement to the centerline joint.
Small strips of purple insulation foam were glued to the wingtips. Now the wing can be shaped with sanding blocks. Once this is done, the ailerons are cut from the wing.
I dont have a detail of it now, but a 1/4 inch aluminum tube with some bits of concentric size tube, is used to make a hinge spanning the entire length of the aileron.
Before gluing the aileron and hinge to the wing, the wing and surface are completely sheeted with aluminum foil. Im using some extremely cheap foil because it is the thinnest i can find. I am adhering the aluminum using some epoxy mixed with glass balloons for lightening.
This process does not feel proper or pretty. The aluminum likes to wrinkle immediately with flexes in the airframe. Carry on though, and when large surfaces start to shine, you wont care about wrinkles. Be careful not to get grubby fingers on the aluminum. You cant sand it off. Use alcohol immediately.
Thats all for this post. Wing comes in at around 100grams, which i dont think is very bad. The fuselage contains more pink foam which will stack up the weight quickly.
Also, if anyone noticed, i completely forgot to incorporate my landing gear. This will get keyed into the spars later.
Wingspan: 36"
Predicted weight: 400grams
![30657299_984548645047692_1330274717280655523_n.jpg 30657299_984548645047692_1330274717280655523_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177738_bf08912df9a35e7a6db47a4d2041aa4b_thumb.jpg)
The wing is built on top of a thick piece of corkboard that has been glued to a wooden board. The planform of the lower surface is cut and pinned to the work surface. I applied a wide strip of plastic tape underneath where I glued the leading and trailing edges.
![30657166_984542241714999_2458865378461742302_n.jpg 30657166_984542241714999_2458865378461742302_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177801_ffe474acd12980a4fab7c4a804ea0e31_thumb.jpg)
A box is made on each side to house the aileron servos flush with the lower surface.
![30688230_984542245048332_5172894553568851158_n.jpg 30688230_984542245048332_5172894553568851158_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177737_876812aa7c41ed7cd45a815b44129081_thumb.jpg)
With the servo and servo wiring in place, the upper surface sheet is applied.
![30709293_984542271714996_238307047119198103_n.jpg 30709293_984542271714996_238307047119198103_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177736_a2be0812d6ac3aebd79d16a6a59baf06_thumb.jpg)
I attached the two wing halves before attaching the upper surface on one side. This was so i could add reinforcement to the centerline joint.
![30705559_984542285048328_2978377503092631450_n.jpg 30705559_984542285048328_2978377503092631450_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177733_ba0aa1755c25a02c6e4f321f6c4b5ff1_thumb.jpg)
Small strips of purple insulation foam were glued to the wingtips. Now the wing can be shaped with sanding blocks. Once this is done, the ailerons are cut from the wing.
![30725058_984542311714992_8091860981840060296_n.jpg 30725058_984542311714992_8091860981840060296_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177734_425161f39f9fe940313254112bb55972_thumb.jpg)
I dont have a detail of it now, but a 1/4 inch aluminum tube with some bits of concentric size tube, is used to make a hinge spanning the entire length of the aileron.
Before gluing the aileron and hinge to the wing, the wing and surface are completely sheeted with aluminum foil. Im using some extremely cheap foil because it is the thinnest i can find. I am adhering the aluminum using some epoxy mixed with glass balloons for lightening.
This process does not feel proper or pretty. The aluminum likes to wrinkle immediately with flexes in the airframe. Carry on though, and when large surfaces start to shine, you wont care about wrinkles. Be careful not to get grubby fingers on the aluminum. You cant sand it off. Use alcohol immediately.
![30704886_984542318381658_5429175368286536352_n.jpg 30704886_984542318381658_5429175368286536352_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177742_4654d7648d98bf842908a27e7885fac7_thumb.jpg)
![30657033_984542358381654_6380510990049689078_n.jpg 30657033_984542358381654_6380510990049689078_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177743_dcb0cac6e05a01566e5ac34c7b226af0_thumb.jpg)
![30707720_984542381714985_644904317134448510_n.jpg 30707720_984542381714985_644904317134448510_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177744_178e536aabb1e2268ed1c6ae5ec76c01_thumb.jpg)
![30714619_984542408381649_1530223010056779961_n.jpg 30714619_984542408381649_1530223010056779961_n.jpg](https://ftforumx2.s3.amazonaws.com/2018/04/177745_d47a10fd5df5b2b77fe02cf7452b646f_thumb.jpg)
Thats all for this post. Wing comes in at around 100grams, which i dont think is very bad. The fuselage contains more pink foam which will stack up the weight quickly.
Also, if anyone noticed, i completely forgot to incorporate my landing gear. This will get keyed into the spars later.
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