Purchased the pre-cut foam
when I got the wing cores.
Macro
the two rudder foam cores using the foam block that the where cut from to
hold them strait with core line as the indicating mark.Nails
used to hold in place till cured.Glassing
the rudder bottoms using the foam blocks as jigs to hold them off the
workbench clear for glassing.Glass
trimmed ready for side two.
More
or the same on the other side.The
support foam is cut away before glassing begins. Fish tail has been cut and
sanding complete.
Glassed
with peel-n-ply.
This is the layout of the antennas.
Lay
out of rudder tip foam before glassing you add 1" foam, the
shaping of the tip from the polyurethane foam is easer.
Macro
with sand bag weights till cure
Sand
sides to match rudder shape. The tan foam is much easer to shape into a
pleasing rudder tip.
In
these picture you see the two rudders with the antennas one with the co-ax
cable and the other just the copper foil tape.
Rudder
antennas one in each rudder. I used tooth picks to hold the co-ax down.Glassing
the rudders with bid re-enforcement layup. To hold the rudders in place I
used duck tap and nails.
Once
again I used the aluminum angle and small clamps to make sure the trailing
edge is true and strait.
The
leading edge of the right rudder had some air bubbles I missed, so I drilled
small holes and pumped in macro to fill the air bubbles.
The
right rudder foam did not cut clean on the first side glass which I think
left larger voids than normal and I did not put thick macro on to fill them.
Cutting
the wing tip, marking the foam that will be removed to allow the glass
re-enforcement layup. Using the rudder to create the cut line. Made the
depth line with a protractor, with the curves it was a fast and easy way to
lay out the guide lines. You might notice the cut foam peaces on the wing,
the rough length of each wing meant that the amount of wing tip removed was
not the same. The right wing was a little longer than the left, but once all
measurement and cuts made they are now identical. So don't worry as I fist
did when I discovered the difference.
Once
all is true and measurements as correct I used 5 minutes to hold the rudders
in place.
Blocks
of foam and nail to prop up the rudder till glassing and support bracing is
in place
In
this shot you can see the cable and how the rudder is just lipped on the
wing with the 5 minutes holding strong.Right
wing shown here, all the lines are used to check the depth of the removed
foam in the next few steps of the re-enforcement glass lay-up.
In
this shot you can see the 5 minute holding the rudder and wing together.
Left wing here.
Just
enough room above the rudder in my garage.
Hot
glued support bracing used to make sure no movement.
Scrap
foam used to hold the rudder high enough off the floor.
Foam
marked for removal, internal glass layup. I used a 1/8" dia. 2 1/2" long
dremel rasp to clear the foam and macro down to glass.
Glass
with flox fills the opening with foam wedges about 1" X 1". The foam is
pushed in that displaces the extra flox leaving no air gaps. In the left
hand corner you can see the radio cable going into the conduit near the wing
tip. I used a 1/4" dia. 24" long drill bit.
Cleaned
out the foam pocket for the hidden bell crank. The pin locates the point of
rotation the bell crank mounting area can not go past this mark.
Here
you see the bell crank in place glass and floxed foam filler block. The wood
block keeps the rudder conduit off of the crank till cure.
Here's
the block of foam on top of the inside glass with macro filling and air
spaces.
The
end of the rudder cable conduit is just visible. The green painters tap is
there to make an easy clean up once all the macro has oozed out of the
joints.
Right
side same as the left above
Right
side foam contoured and hidden bell crank waiting for cure.
Here
you can see the pocket for the hidden bell crank movement.
Completed
foam contoured
It
took a long time and a lot of web searching to find out how this foam should
look. The multi dimensional shapes made it a real mind bender.
In
this shot you can see the brown packing tape covering the filler foam for
the bell crank pocket. The filler foam is not glued in because it is dough
out later creating the void area for the crank.
This
is after glassing the reinforcement from bottom wing to outer rudder. The
brown packing take makes is easer to clean out the foam later on.
A
little bigger shot of the glass work, it was fun to see how the layer after
layer of glass changed the wing and rudder making them one.
Right
same as left
Mounting
the bottom rubber half using an aluminum angle to keep the trailing edges in
line.
Two
5 lbs sand bags holding down the rudder bottom till cure.
In
this shot you can see some tape hold the leading edge from moving out of
alingment.
This
was a very interesting lay up giving the strength to the rudder and wing
connection to the point I think it would withstand a tremendous load amazing
construction.
Each
play of Bid is an inch smaller as you can see in the tick marks show the
edge of each ply. It just so cool...
Left
wing rudder same as right.
The
second time around I get better and didn't need the tick marks.
Rudder
control surface cut free and set in foam blocks getting the internal glass
layup. Did the rudder internal at the same time.
Rib
glassed waiting for cure and knif trim
Hinges
in place, aliment using aluminum angle as seen on other hinge mounts.
Glass
rig on rudder.
In
this shot you can see the spring and hidden bell crank pockets.
Hot
glued the sticks to hold the hinge halves up for mating with the rudder
control surface.
The
rudder side of the hinge will be removable as the control side will be pop
riveted in place and floxed.
With
the rudder control surface aligned to locate the rivet holes I shined a
light on the back side of the rudder. Then using a drill made the holes in
the control surface.