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How to sheet a fuselage with plywood
Once assembled, use a long piece of small section wood and lay it along the length of the fuselage and check for any irregularities. Any hollows can be rectified by gluing a piece of balsa to the edge of the former and then sanding to shape. Using the same procedure, you can now taper all the formers to follow smoothly the fuselage contour. Increase the glue area of the keel longerons by filling between the formers with balsa and tapering to the fuselage contour. Refer to drawings below. This preparation is essential for a good finish..
Start from the front of the fuselage and working towards the rear. Cut a piece of card whose width is approximately 1.5 times the distance between the 1st and 2nd former and of sufficiet length to lay completely over the first bay as a template. Mark the extreme left and right hand points on the card and whilst holding it securely in place trace the shape of the first panel from the underside. Make sure you are using a sharp pencil.
Now you can cut ot your first panel from 0.4mm ply and epoxy into position. By keeping a centreline marked on your plywood, you will be able to use the radius of the rear cut of your template as the front of your next. Repeat this process for the remainder of the fuselage, but these panels can be glued in place by using impact adhesive (Evo-Stick). For example, after cutting out panel 2, apply the glue to the formers and the panel and leave on one side to dry whilst working on panel 3. By this time panel 2 will be ready to apply. You will notice that as you proceed along the fuselage the shapes will begin to chage
When the second side is completed, a certain amount of filling will be rquired over the panels to obtain a smooth curve at areas, such as the nose, where there is an acute radius to the panelling as shown below
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