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First you must make the yardstick spar:
Before moving to the next step, use a straightedge lined up on the Leading Edge Fold Line (clamp it down if you need to) and, using a medium to large Philips head screwdriver, score the Leading Edge Fold Line several times. You don't want to cut through the coroplast, but you certainly want to beat it down such that you can fold it back and forth to get a good leading edge. It helps to fold the top part of the wing either over the straightedge itself, or perhaps over a table edge so that you get a nice straight fold. Once the leading edge is scored and folded back and forth a few times, you may move to: Once the spar is dried on the left side, run hot glue along the TOP of the spar AND at the trailing edge (where the top will meet with the bottom, and then carefully fold the wing half down and hot glue it to the bottom half. You may need to do it in two steps (first glue the top of the wing to the top of the spar, and then glue the trailing edges together). In either case, use a 2x3 or 2x4 to help you evenly hold down the top of the wing onto the bottom of the wing. While you are doing this, make sure to keep the leading edge held down if possible so that the resulting airfoil is a flat-bottom airfoil. There will be a small overlap that you will trim off. Save the overlap for later!! You will use it for the center wing wrap. Once the left side is done, do the same with the right wing half. This is what it looks like halfway through:
You should end up with a wing that looks like this:
with a nice airfoil like this:
Now you need to wrap the center of the wing to hide the cut and also for some strength:
Congrats! Your wing is now done. Decorate as necessary (except DO NOT do a lousy stinky stencil job like I did!).
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Last Updated:
10.09.2006 The site that started it all: Spadtothebone.com
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