RE: AJ-2 Construction Revisited

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RE: AJ-2 Construction Revisited - 5/27/2012 12:48 AM

sahartman21

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On the second wing the hole overlapped the carbon fiber laminant. Don't cut the carbon as it provides strength at the wing center section.

I slid the 1/8" thick plywood plate under the carbon fiber and left it intact.

The wing center section is covered with several layers of fiberglass cloth. The carbon laminant will not be exposed.

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RE: AJ-2 Construction Revisited - 5/27/2012 3:41 AM

sahartman21

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Temporarily attach the wing with masking tape.

Locate the rear wing mounting holes

Remove the wing and use a hole drill as needed.

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RE: AJ-2 Construction Revisited - 5/27/2012 7:27 PM

sahartman21

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Pieces of 3/4" diameter dowels are glued in place with an epoxy micro-balloon mix.

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RE: AJ-2 Construction Revisited - 5/27/2012 7:29 PM

sahartman21

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One inch square pieces of 1/4" thick plywood are glued in place with Shoe Goo.

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RE: AJ-2 Construction Revisited - 5/28/2012 2:23 AM

D.E.

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looks good,,,, two is better than one! and can be built almost as fast as one.

how are you getting your pics to load? I tried a couple of times but got error message both times.

DE

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Post #: 30

RE: AJ-2 Construction Revisited - 5/28/2012 3:40 AM

sahartman21

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I set the camera at low resulution.

When loading I have to load 1 picture at a time.

Scott

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Post #: 31

RE: AJ-2 Construction Revisited - 5/28/2012 4:08 AM

sahartman21

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Here are some pictures of servo tray installation.

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RE: AJ-2 Construction Revisited - 5/29/2012 12:58 AM

sahartman21

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Here are some pictures of the wing tip installation:

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Post #: 33

RE: AJ-2 Construction Revisited - 5/29/2012 1:02 AM

sahartman21

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A piece of window sheer is tacked in place using 3M77. This plus the fiberglass cloth makes the aileron hinge.

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RE: AJ-2 Construction Revisited - 5/29/2012 1:05 AM

sahartman21

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Some 2 ounce fiberglass cloth was used instead of 3/4 ounce cloth.

Three more layers of fiberglass cloth were tacked in place at the wing center section. The widths were approximately 11", 9", and 7 ".

Approximately 1.5 ounces of finishing epoxy was used on each side of the wing or a total of 3 ounces of finishing epoxy.

The wing was then placed between layers of peel ply (nylon fabric) and placed in a vacuum bag. The finishing epoxy needs to dry approximately 8 to 12 hours before attempting to remove the wing from the peel ply.

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RE: AJ-2 Construction Revisited - 6/1/2012 3:03 AM

sahartman21

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The wing was removed from the peel ply and it was cleaned up a little.

I use a sanding block to trim the excess fiberglass from the trailing and leading edges.

Lightweight Spackle is spread on with a squeegee to fill up the pores and low areas.

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RE: AJ-2 Construction Revisited - 6/4/2012 1:14 AM

sahartman21

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Here are some pictures of adding the aileron torque rods and making the skinned hinges.

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RE: AJ-2 Construction Revisited - 6/4/2012 1:18 AM

sahartman21

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The wing is still light at this point. It weighs about 15.55 ounces.

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RE: AJ-2 Construction Revisited - 6/6/2012 3:33 AM

sahartman21

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The aileron servo is installed in the following pictures.

This method avoids cutting a big hole in the top of the wing that can reduce wing strength.

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Post #: 39

RE: AJ-2 Construction Revisited - 6/11/2012 2:39 PM

sahartman21

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The wing and landing gear are installed in the following pictures:

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RE: AJ-2 Construction Revisited - 6/11/2012 7:11 PM

PylonDave

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Do you tape the belly pan on or is it glued??

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Post #: 41

RE: AJ-2 Construction Revisited - 6/11/2012 7:41 PM

sahartman21

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At this point the belly pan is just stuck in place with tape.

You can build it like you want it. If you glue it on, then there needs to be a split to allow for the landing gear.

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Post #: 42

RE: AJ-2 Construction Revisited - 6/11/2012 7:53 PM

sahartman21

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The horizontal tail surfaces are shaped in the following pictures:

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Post #: 43

RE: AJ-2 Construction Revisited - 6/11/2012 7:57 PM

sahartman21

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A layer of window sheer is tacked in place on the top surface.

Additional pieces of 2 ounce fiberglass cloth is applied over both the top and bottom surface.

Finishing epoxy is squeegeed over the surface.

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RE: AJ-2 Construction Revisited - 6/11/2012 7:59 PM

sahartman21

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The tail surfaces are placed between layers of peel ply and placed in the vacuum bag.

The bag consists of 4 mil plastic sealed with latex caulking.

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Post #: 45

RE: AJ-2 Construction Revisited - 6/11/2012 10:18 PM

sahartman21

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The tail surfaces were removed and cleaned up with a sanding block.

Lightly sand the surface with 220 grit sandpaper on a sanding block.

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Post #: 46

RE: AJ-2 Construction Revisited - 6/16/2012 11:26 PM

sahartman21

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Some planning was done on routing of the flexible cable.

Use a nylon connector with the metal control horn. This prevents the hole in the control horn from gradually wearing and getting too big.

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< Message edited by sahartman21 -- 6/18/2012 1:30 AM >

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Post #: 47

RE: AJ-2 Construction Revisited - 6/16/2012 11:28 PM

sahartman21

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A slot is cut with an exacto blade.

This is followed with a cut off wheel.

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Post #: 48

RE: AJ-2 Construction Revisited - 6/16/2012 11:31 PM

sahartman21

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A large control horn is made from 3/32" wire, wheel collars, and sheet metal.

Parts are soldered together with silver solder.

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Post #: 49

RE: AJ-2 Construction Revisited - 6/16/2012 11:34 PM

sahartman21

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The control horn is tacked in place with CA glue.

A mixture of finishing epoxy and micro-balloons is applied in the gap.

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Post #: 50

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