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  1. #51

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    RE: AR-6 Construction Thread

    The wing will weigh about 15.4 ounces after installing the torque rods.
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  2. #52

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    RE: AR-6 Construction Thread

    In case you didn't catch on. Here is the second wing being glassed.


    1) Begin by tacking on a piece of window sheer over the top surface of the ailerons. The purpose is to provide a hinge surface.

    2) Tack a layer of 1.6 ounce fiberglass cloth over the entire surface of the wing.

    3) Tack another layer of 1.6 ounce fiberglass cloth over the wing tips.

    4) Tack a wide (15.5") piece of fiberglass cloth around the center of the wing.

    5) Follow with 3 more layers of fiberglass cloth (each getting gradually narrower) around the center of the wing.

    6) Mix about 1.5 ounces of finishing epoxy. Add 10% more 91% alcohol to thin the epoxy. Drizzle this over one side of the wing and use a squeegee to spread out the epoxy. Do the other side the same way.

    7) Place the wing between layers of nylon fabric (peel ply).
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  3. #53

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    RE: AR-6 Construction Thread

    More pictures:

    8) Put the wing in the vacuum bag and apply about 5" Hg vacuum to the wing.

    9) It's cold so the vacuum bag was placed between layers of electric blanket. This warms the epoxy enough that it dries.
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  4. #54

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    RE: AR-6 Construction Thread

    Gary provided some background on the AR-6. The Sportsman Pilot article is real interesting.

    Thanks Gary!

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  5. #55
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    RE: AR-6 Construction Thread

    ORIGINAL: sahartman21

    Gary provided some background on the AR-6. The Sportsman Pilot article is real interesting.

    Thanks Gary!


    You're Welcome, Have Fun!
    Gary James
    AMA CD 68845, NMPRA 15I, RCCA #908

  6. #56

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    RE: AR-6 Construction Thread

    On a recent project the first flight showed that there was a slight twist in the wing.

    I chose to check the wing on the AR-6 before proceeding to the next steps.

    Should there be a twist, it can be removed by heating the wing (with a heat gun or heater like shown here) and twisting it in the opposite direction of the twist.

    Remove the wing from the heat and continue holding until the wing is cool.

    Recheck the wing at several locations to confirm the wing is straight.



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  7. #57

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    RE: AR-6 Construction Thread

    The following pictures shows the installation of ailerons.

    They are going to be configured like the ones on the yellow wing.

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  8. #58

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    RE: AR-6 Construction Thread

    More pictures:

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  9. #59
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    RE: AR-6 Construction Thread

    Scott, On the kitchen table ??? Must be cold in the garage!! :-)

  10. #60

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    RE: AR-6 Construction Thread


    ORIGINAL: PylonDave

    Scott, On the kitchen table ??? Must be cold in the garage!! :-)

    I didn't think the epoxy would dry in the cold garage, so I brought the wings inside to dry.

  11. #61

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    RE: AR-6 Construction Thread

    I used a Dremel tool to remove the majority of excess epoxy & micro-balloon mix. This was followed by using a scrapper blade to bring the surface flush.
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  12. #62

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    RE: AR-6 Construction Thread

    The wings weigh in at 14.95 and 15.4 ounces. Both are relatively light and allow a couple ounces for a painted finish.

    My wings are ready to fly at nominally 19 to 21 ounces with the servo.

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  13. #63

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    RE: AR-6 Construction Thread

    Lightweight Spackle is spread over the surface of the wing fill low spots.

    The surface immediately in front of the hinge material (window shear) should be filled in this step.
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  14. #64

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    RE: AR-6 Construction Thread

    The horizontal tail surfaces are made from 3/8" light balsa sheet.

    I've enlarged the tail a bit to get a tail about 16".

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  15. #65

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    RE: AR-6 Construction Thread

    The following pictures shows the installation of 1/64" thick plywood strips into the edges of the horizontal tail surface:
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  16. #66

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    RE: AR-6 Construction Thread

    A Dremel tool and cutoff disk are used to cut the hole for the horizontal stabilizer.

    Fiberglass and carbon fiber dust is present during the cutting. I used a respirator to protect my lungs.
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  17. #67

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    RE: AR-6 Construction Thread

    One inch square pieces of 1/4" thick plywood are glued in place for use as wing hold down blocks.
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  18. #68

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    RE: AR-6 Construction Thread

    The tail surface is shaped in the following pictures. Most of the actual shaping was done with a sanding block with coarse sandpaper (80 grit).
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  19. #69

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    RE: AR-6 Construction Thread

    The following pictures shows the installation of skinned hinge and fiberglass cloth on the tail surface:

    A piece of window sheer (chiffon) is tacked to the tail surface.

    Pieces of 1.6 ounce fiberglass cloth are tacked over the window sheer and other side.

    Apply finishing epoxy over the surface of the cloth. A plastic squeegee is used to spread out the glue.

    Tail surfaces are placed between layers of peel ply (nylon fabric).

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  20. #70

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    RE: AR-6 Construction Thread

    More pictures:

    The vacuum bag is made from 4 mil thick pieces of plastic tarp.

    A layer of paper towel is applied on top of the surface before closing the bag.

    Latex caulking is used to seal the edges.

    The vacuum pump is set to pull about 5" Hg.

    It is cold outside and therefore the parts were placed between layers of electric blanket to raise the temperature enough that the epoxy will dry.
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  21. #71
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    RE: AR-6 Construction Thread


    ORIGINAL: sahartman21

    The following pictures shows the installation of skinned hinge and fiberglass cloth on the tail surface:

    A piece of window sheer (chiffon) is tacked to the tail surface.

    Pieces of 1.6 ounce fiberglass cloth are tacked over the window sheer and other side.

    Apply finishing epoxy over the surface of the cloth. A plastic squeegee is used to spread out the glue.

    Tail surfaces are placed between layers of peel ply (nylon fabric).


    Scott , is this a 1/4 inch balsa stab ??

  22. #72
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    RE: AR-6 Construction Thread

    Oh I see that it is 3/8 inch. Sorry

    I wonder about sandwiching some 1/64 ply between say two 1/4 inch light balsa pieces to create a little thicker airfoil.

    Have you ever tried that ?

  23. #73

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    RE: AR-6 Construction Thread


    ORIGINAL: PylonDave

    Oh I see that it is 3/8 inch. Sorry

    I wonder about sandwiching some 1/64 ply between say two 1/4 inch light balsa pieces to create a little thicker airfoil.

    Have you ever tried that ?
    The wood Sam-Rai tail surfaces are constructed with a 1/64" thick piece of plywood (with lightening holes) between layers of balsa wood. This works OK, but is heavier than wood that just has 1/64" ply added at the edges.

    Initially I was apprehensive about shaping the 3/8" balsa sheet. It was actually easier than I thought and the second tail surface was shaped in about 20 minutes. The razor plane and sanding block work wonders on balsa.

  24. #74

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    RE: AR-6 Construction Thread

    The tail surfaces were removed from the vacuum bag.

    I cut off the caulking so it doesn't get it all over.

    Use a sanding block to trim the edges and smooth out the surface.
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  25. #75

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    RE: AR-6 Construction Thread

    The following pictures show the attachment of the wing to the fuselage:
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