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Measure and cut a 2-mil sheet of Coroplast to the specifications shown. You'll need 4-mil Coro for the Ailerons. We have tried using 2-mil Coro for ailerons and it just doesn't work well. Flexes too much and has a tendency to get its hinges torn on repeated landings.
Place the sheet on your Wing Jig and anchor it using small clamps.
Using a Phillips screwdriver and a straightedge, carefully score the Leading Edge line and the Spar line to weaken the flutes. Build your spar from two yardsticks. Cut 1' off of each yardstick. Use one of the 1' scrap pieces as a lap to join the two 2' pieces together. There is NO dihedral in this wing, so glue the pieces straight together.
Carefully run a bead of hot glue down the spar line on the wing. When you scored the spar line, you created a little trough for the glue to stay in. Install your spar into the spar line and hold down straight until the hot glue dries. Mount the wing into the Wing Jig and anchor with clamps:
Carefully run a bead of hot glue down the top of the spar. Using another 4 foot piece of 2x4 or other long instrument, lower the top of the wing down onto the spar and hold until the glue dries. Ailerons: Carefully place your ailerons into position on the bottom half of the wing. They should be 1" inside the wing with 1.25" hanging outside of the wing. Mark where they are laying onto the inside of the wing. Remove the ailerons, lay down hot glue, and then put the ailerons back onto the glue. Use a 2x4 to hold down the aileron to the bottom of the wing until the glue dries. once both ailerons are glued to the BOTTOM of the wing, then lay beads of hot glue onto the TOPS of the ailerons and, using a 2x4 fold the TOP of the wing down onto the ailerons and hold until the glue dries. Here is what you should end up with:
Now carefully cut off one bottom flute of the aileron near the trailing edge of the wing. This forms your hinge. Flex the aileron several times to make sure it moves easily.
Now it's time to install the aileron servo. Cut a piece of scrap 2-mil in a square shape. Hot glue or CA it to the wing in the center with the top part just below the spar. Cut a hole through the 2 layers of 2-mil to fit the servo in. Try to make the hole just barely bigger than the servo so that the servo fits very tightly. Before you actually install the servo, reach through the hole, up next to the spar, and poke your knife or ice pick through the coro to the underside of the wing. Turn the wing over and cut a small (1" x 1") hole for the servo wire to come through. Final holes should look like this:
Hook up control rods to the horns and to the servo arms. Test the servo action and adjust accordingly. You will probably have to make a slight 45 degree bend in the middle of the control rods to accurately position everything and eliminate binding. The wing is now done!
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Last Updated:
10.09.2006 The site that started it all: Spadtothebone.com
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