Scale Soaring UK

...using beech blocks to make the servo holder from, I did cut a sleeve in them just fitting the attachments lips.
A firm ply was cut to fit the angled supporting blocks. These were cut to the proper aligning of the servo to the airbrake.
The hole for the servo arm etc, was cut, all glued together and screwed too, to make sure the airbrake servo never would break free from the base ply! Murphy you know…
A wide headed screw holds the servo in place.

...around the servo, reinforcements are glued in to screw the servo cover onto later.
For the aileron servos the same work was done more or less...
The only thing was the servo arm operates different so this was also sorted in a scale way.
The small supporting wheel mid wing, is held in place by a beech block.
The servo arm on the aileron was made in balsa and shaped to the wing ribs.
...

... now the servo wiring had to be made to length.
I use the cut the wires and solder a long lead on, and in the end a MPX plug to fit the plug in the fuselage.
Now the wing is so far ready that the bottom spar can be made and placed in the gutter again...
But before that can be done I need the most important bit of the wing building: “ The guides !”
These are cut from foam which are so made that the wash out on the wing fits these guides 100%!

... the cutting of the R-Glass or S-glass roving is done on my table. I know how many strings I need to fill the gutter with them. One string contains 2400 very fine endless threats. Is used in real gliders wings too or Carbon…
I wind the roving around screws on the table. Afterwards I just cut them lose on the screw. The epoxy is going on them and the white shining color has to go. This way I know the epoxy is fully around all the threats. With an old back card or so, I rub the too much epoxy off as much as possible.
There will be always too much... But no harm done this sees to it that all is properly glued together in the end!
Also a balsa strip is closing the gutter off so the roving is squeezed again to all parts, the shear webs and all the rest...
Metal block do the job here.
The wing stays on the foam guides until the epoxy is set!

... when the spars are set for a day I start to plane down the balsa strip to the shape of the wing again and grind it down at the end.
That way the wing is ready for the sheeting at the bottom too.
Very important now that the foam wing supporting blocks stay perfectly in place under the wing.
The TE is extra under filled by a scrap balsa block so this TE will be straight in the end.

... and more...
And yes they both have the same shape mirrored, TOP ON!!!
Now so far done but the most important thing misses still, the LE!!!...

...the LE is for me always a 10 mm balsa strip cut to fit.
Plane it down to a almost right shape and then the sanding starts.
This is the most important bit of all the wing. It flies much better when done as perfect as one can get it!
So some time and dust later, all is ready to work now on the ailerons...
To mark the aileron on the bottom too, you drill from the top wing side down into the bottom sheeting.
This way you can draw a line top and bottom to mark the cutting line...

... the cutting line is about 2 mm wide so no problem cutting down the line.
All is sanded down to the aileron spars, both on the wing and on the aileron itself.
On the aileron the spars are build in at an angle for the movement of the aileron downwards.
Both holes are now sealed off by a strip of 0.6 mm ply to have the full torsion stability of the ailerons.
This has to be done with care not to deform the aileron from the wing wash out!!!
I use wood glue to do this, because the height is to small and contact glue. It is to flexible for this job at the beginning.
Later it hardens out more, I know this from the Boeing Scout wing. But I learned from it that I need more firmly closing of the boxes, both on the wing and the ailerons...
The aileron control arm, was cut from Epoxy plate 1.5 mm, as well as the control linkages...

...now the wing was ready for a fit to the fuselage at that time.
And as expected, it was a perfect!
One small part needed to be made, the airbrake!
Here I kept it simple too.
On a 0.4 mm ply I build a frame in balsa 1/4". in the cutout of the airbrake in the wing I put a scrap piece of ply 0.6 mm and grinded the balsa down to fit the top wing contour. Now a top ply could be glued on and sanded to fit the wing cutout with some play on all sides.
I marked the brake control arm and milled it out.
All parts ready now to cover the wing open places. With that done the wings are now waiting for the painting with some warmer weather to do this!!!
Noël

With the wings ready to paint, the fuselage was back on to finish a little further.
The seat was first to be installed so that the new wing retainer system could be reached at all times with less effort.
That was easy due to make a hole in the seat epoxy base lining. A cushion will be put on top to cover the hole and more.
The seat cushion was made by sewing it together with a foam inlay to have a nice soft seat for the pilot. The magnetic safety belts were fitted as well so the pilot and the cushion could be taken out easy to get to the wing retainer system with the LH/RH turnbuckle.