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AJ-2 Construction Revisited

Old 05-26-2012, 03:48 PM
  #26  
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Default RE: AJ-2 Construction Revisited

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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Old 05-26-2012, 06:41 PM
  #27  
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Default RE: AJ-2 Construction Revisited

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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Old 05-27-2012, 10:27 AM
  #28  
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Default RE: AJ-2 Construction Revisited

Pieces of 3/4" diameter dowels are glued in place with an epoxy micro-balloon mix.
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Old 05-27-2012, 10:29 AM
  #29  
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Default RE: AJ-2 Construction Revisited

One inch square pieces of 1/4" thick plywood are glued in place with Shoe Goo.
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Old 05-27-2012, 05:23 PM
  #30  
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Default RE: AJ-2 Construction Revisited

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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Old 05-27-2012, 06:40 PM
  #31  
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Default RE: AJ-2 Construction Revisited

I set the camera at low resulution.

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

Scott
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Old 05-27-2012, 07:07 PM
  #32  
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Default RE: AJ-2 Construction Revisited

Here are some pictures of servo tray installation.
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Old 05-28-2012, 03:58 PM
  #33  
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Default RE: AJ-2 Construction Revisited

Here are some pictures of the wing tip installation:
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Old 05-28-2012, 04:02 PM
  #34  
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Default RE: AJ-2 Construction Revisited

A piece of window sheer is tacked in place using 3M77. This plus the fiberglass cloth makes the aileron hinge.
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Old 05-28-2012, 04:05 PM
  #35  
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Default RE: AJ-2 Construction Revisited

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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Old 05-31-2012, 06:03 PM
  #36  
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Default RE: AJ-2 Construction Revisited

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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Old 06-03-2012, 04:14 PM
  #37  
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Default RE: AJ-2 Construction Revisited

Here are some pictures of adding the aileron torque rods and making the skinned hinges.
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Old 06-03-2012, 04:18 PM
  #38  
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Default RE: AJ-2 Construction Revisited

The wing is still light at this point. It weighs about 15.55 ounces.
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Old 06-05-2012, 06:33 PM
  #39  
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Default RE: AJ-2 Construction Revisited

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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Old 06-11-2012, 05:39 AM
  #40  
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Default RE: AJ-2 Construction Revisited

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

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Old 06-11-2012, 10:11 AM
  #41  
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Default RE: AJ-2 Construction Revisited

Do you tape the belly pan on or is it glued??
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Old 06-11-2012, 10:41 AM
  #42  
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Default RE: AJ-2 Construction Revisited

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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Old 06-11-2012, 10:53 AM
  #43  
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Default RE: AJ-2 Construction Revisited

The horizontal tail surfaces are shaped in the following pictures:

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Old 06-11-2012, 10:57 AM
  #44  
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Default RE: AJ-2 Construction Revisited

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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Old 06-11-2012, 10:59 AM
  #45  
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Default RE: AJ-2 Construction Revisited

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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Old 06-11-2012, 01:18 PM
  #46  
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Default RE: AJ-2 Construction Revisited

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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Old 06-16-2012, 02:26 PM
  #47  
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Default RE: AJ-2 Construction Revisited

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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Old 06-16-2012, 02:28 PM
  #48  
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Default RE: AJ-2 Construction Revisited

A slot is cut with an exacto blade.

This is followed with a cut off wheel.
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Old 06-16-2012, 02:31 PM
  #49  
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Default RE: AJ-2 Construction Revisited

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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Old 06-16-2012, 02:34 PM
  #50  
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Default RE: AJ-2 Construction Revisited

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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