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  1. #1
    KitBuilder's Avatar
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    Great Planes 40 Clipped Cub Kit Rebuild

    I crashed my GP 40 Clipped Cub kit early last year losing it down low in the sun. Nose is smashed and the wing has damage. One side worse than the other but both sides have the tips gone. cracked or missing ribs.. section of LE gone, etc. I have started repair work and have the wing about 90% done. I'll try to post pics soon of the progress..
    Mike -
    I was born a pilot... 100 years to late.

  2. #2
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Here are some before and after pics so far
    The wing is just about finished other than covering and the LE sheeting that is drying on the sde that received the most damage. I cut it all away and rebuilt it. The gear has some damage which I plan to straighten rather than re-create. Will need to fix up the balsa cross bar at the top and the check covering. Fuse is where I am now showing the front gone... Vertical supports in the cabin are no longer good but still there and need fixing, The nylong wing bolts were sheared off and remain in the hardwood blocks. The wing front dowels had one sheard off flush so I still need to drill that out and install another. That will be done when I have the cabin back together and can properly aling the dowel in the new hole. The struts on both sides survived but my home made jury's need to be recreated from the streamlined alum tubing with all four having some type of crease in them.

    I have the plans so I should be able to get everything back the way it was. Next step is to clean up the fuse back to the solid pieces and decide which ones just need some re-inforcement.
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    Mike -
    I was born a pilot... 100 years to late.

  3. #3

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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Glad it will be reborn! It was nice model.

  4. #4
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Yes...I'm excited to be getting back to it and f lying her again (not through the sun this time )

    I cleaned up the nose of the jagged edges and cleaned up the eppxy as best I could. Cut a new firewall from the plan with all the recesses and slots of the original. I do have the lower portion of each side of the fuselage in tact to help me locate it on the nose and there is right thrust only if I remember from looking at the plan. I'll have to verify that before I install it. The tank floor extended to the firewall fitting in slots and that's where I am now. The very forward section of the floor was destroyed so that was cut back. I'm making a new "forward" piece to mate up to the existing original with tabs on firewall side that fit into slots in the lower section of the firewall. This forward section had the proper right thrust angle so I need to get this correct. Once that is in place, I think it will go pretty quick from there recreating the nose and top section until I get to the wing mount area. I have to work this evening so I hiope to post some pics later.
    Mike -
    I was born a pilot... 100 years to late.

  5. #5
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Pics show cleaned up nosed and the copy of the firewall from the plans I 3m sprayed to some card stock to draw an exact outline. Cut and sanded the firewall and attached at the base to the fuse structure that was still there. I lined the fuse up over the plan to be sure I had the correct right thrust and there is no downthrust. Once the epoxy cures I'll go about rebuilding the nose around it. I'm going to add another tank flooor over what is there to ensure a solid connection. I originally thought I could keep the bottom front piece but after looking more closely it was pushed in and I removed the wholed thing. I had a heavy hub on the front so I"m not to concerned about a little extra weight. Maybe when done, I can go with a standard prop hub.
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    Mike -
    I was born a pilot... 100 years to late.

  6. #6
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Started building out the front sides tonight and while drying began fixing some vertical supports in the window area. I'll post pics after all the clamps are removed.
    Mike -
    I was born a pilot... 100 years to late.

  7. #7

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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Wow, good progress.

  8. #8
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Plan to get back to my build this evening. Had some major PC data loss and work issues taking lots of time . Went to the LHS today to pick up some ply and balsa-tri stock to continue repair of the nose and cabin area. Also some teardrop aluminum tubing to re-create my jury struts. Hope to get lots done tonight as the kids have friends over so I should some uninterrupted time
    Mike -
    I was born a pilot... 100 years to late.

  9. #9
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Only a bit done as our dog went all Cujo...

    I made a template for the top to fit what is already there. Traced on the same thickness ply and need to cutout and install. The replacement cowl I ordered does not fit per the orginal as expected. Taking a closer look I see the firewall is a bit higher 3/16 of an inch due to the bottom NOT being at the correct spot. No biggie. Will reduce the height and begin installing the motormount so I can start closing things up. The same ply is the correct thickness for the front wing mount area as well. I cut all the opening in the cowl and left the protruding piece in my frist build but looking online I dont see it on the full scale cubs. I may angle it back top to bottom or something. I side mount the motor so the 4 stroke looks like the engine on one side and I use the plastic head that came with kit for the other side. I'm not sure if I saw the dummy cyliners this time with the cowl...hmmm. May have to make up something.

    I noticed there was a "dent" in the top front left section from shipping i guess. A small indentation with a small but noticeable crease. Tried pushing against it but does not work... wondering how to get the out if possible. Dont want to heat and end up mucking up the whole thing.

    I assume others do this but I find the starbucks stirers or similar make good clamps for applying pressure in tight places.
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    Mike -
    I was born a pilot... 100 years to late.

  10. #10
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Forgot to post the template pic.. thought some would want to see it.
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    Mike -
    I was born a pilot... 100 years to late.

  11. #11

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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Good progres!

  12. #12
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Reduced the height of the firewall and the clamps are for the plywood cutout from the template piece being epoxied on. The long side has two clamps the short side had the one... the other was added to equalize the weight so it would not fall over. I turned it upside down so the expoxy (15 min) stays put and didnt run down the inside.

    hhe other pic shows the "dent" in the cowl... any ideas on how to get it out or reduce it. I'm afraid to use heat to soften and push it out....

    I thought i would post pics before the fateful day... this is what I'm hoping to get back to... though I'm going to dress up the side differently... not sure what I was thinking with that wierd bend stripe down the side...

    Anyone know how to attach files while your in the intial post. I have to exit then go back in and then i have the upload button???
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    Mike -
    I was born a pilot... 100 years to late.

  13. #13
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    On a business trip the cold white North next week. I did decide to hit use my covering gun on the ABS cowl and it came out ok. The dent is much improved. I'm going to try to work at it a bit more before posting a pic.
    Mike -
    I was born a pilot... 100 years to late.

  14. #14
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Pics of cowl.... looks better than the original dent shot from above. Will try a bit more, then it is what it is. Will work on mounting the motor when I get back and then centering the cowl.
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    Mike -
    I was born a pilot... 100 years to late.

  15. #15
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Have been finishing up a BUSA 1/6 N17 on rcgroiups in the builders workshop. Will pick this up again very soon. I have the front cabin wing support cut and need to pick up same thickness ply for the angled support to finish up the front cabin area.
    Mike -
    I was born a pilot... 100 years to late.

  16. #16
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Got a little more done... the angle support recesses down into the fuse for a good connection. should be able to much more today with the fuse wing mount area.
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    Mike -
    I was born a pilot... 100 years to late.

  17. #17
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Drilled out the sheared off wing mount dowel fore and aft and inserted a new one to test the fit. On the dowel that was unaffected.. i drilled into the front bulkhead and that came out well. Normally I elongate the hole a bit in the main bulkhead and then attach a doubler drilled to the correct sized hole and align the wing that way to get a perfect fit. Work issue now... so hope to expoxy in that new dowel...drill the second hole in the bulkehead and the wing mount will be good. Then back to pretty-ing up the forward section, adding windows, etc.
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    Mike -
    I was born a pilot... 100 years to late.

  18. #18
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Wing dowel in place and fitted to fuse. I will need to place something like a 3/32 shim between the wing and bulkhead as there is a small gap when the rear bolts are installed. Still need to add the doubler on side you see in the pic. Also a shim on each side as the "cheeks" that were part of the fuse up top were destroyed. You can see the gap there. Didnt think about that as i was going along. So far so good though..
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    Mike -
    I was born a pilot... 100 years to late.

  19. #19
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    I added the filler piece and the wing front and bulkhead rear. The windshield fits nice but I need to thin the cheeks just a bit as with the wing on it's a bit snug against the window. I thought I would include a pic of the the Ply doublers I put on the front being clamped. The angle allows the glue to sit in the fillets. Not sure if anyone else does stuff like this to get the correct angle for drying needed.. just curious.
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    Mike -
    I was born a pilot... 100 years to late.

  20. #20
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    I created the cheeks up top from balsa planks laminated. One is attached.. the hole to clear the wing dowel. Needs some final sanding to smooth it out nice.
    Looks like file upload issues at the moment.. will try again later tonight
    Mike -
    I was born a pilot... 100 years to late.

  21. #21
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Back from Brazil work trip and at the Miami airport they had this strange wheel chair contraption hanging and a fairly large transport with propellers spinning. Unfortunately my phone takes awful pics from a distance. Now I'm off to Jax so I will re-start the cub next week.
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    Mike -
    I was born a pilot... 100 years to late.

  22. #22
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Gluing the second cover on right side for the wing dowel. Some final sanding tomorrow then I'm down to mounting the motor and straightening the landing gear. I may make a new set.. not sure yet.
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    Mike -
    I was born a pilot... 100 years to late.

  23. #23
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Large honey-do list this weekend but managed to do some initial cutting on the cowl. Engine has just been placed for now.. not secured.
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    Mike -
    I was born a pilot... 100 years to late.

  24. #24
    KitBuilder's Avatar
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    Needed to cut a bit more from the cowl after locating the motor and drilling holes for where it needs to be. Added the 4 stroke throttle connection and drilled the hole for the throttle pushrod in the firewall. Don't have enough epoxy so plan to pick some up tomorrow for fuel-proofing the front and tank area.

    Anyone know of a place to get soft "bendable" brass or whaterver is supplied with the tanks. The LHSs only seem to carry the stiff stuff that narrow using my bender.
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    Mike -
    I was born a pilot... 100 years to late.

  25. #25
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    RE: Great Planes 40 Clipped Cub Kit Rebuild

    KitBuilder you have done a great job. Looks real good.

    Ken
    \"As for Me and My House, We Will Serve the Lord\"
    Club Saito Member 775
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