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AR-6 Construction Thread

Old 06-08-2013, 11:42 AM
  #151  
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Default RE: AR-6 Construction Thread

Some lightweight Spackle was used to fill voids in the balsa.

The trailing edge was trimmed to the final dimension.
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Old 06-08-2013, 04:08 PM
  #152  
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Default RE: AR-6 Construction Thread

The trailing edge was shaped with a razor plane and followed with a sanding block.

The leading edge was done similarly.
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Old 06-15-2013, 09:38 AM
  #153  
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Default RE: AR-6 Construction Thread

The landing gear blocks are installed in the following pictures:
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Old 06-15-2013, 11:51 AM
  #154  
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Default RE: AR-6 Construction Thread

Below are more pictures on landing gear installation:
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Old 06-15-2013, 04:18 PM
  #155  
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Default RE: AR-6 Construction Thread

Below are pictures showing the shaping of the wing tips:
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Old 06-16-2013, 06:48 AM
  #156  
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Default RE: AR-6 Construction Thread

The following pictures shows getting ready for vacuum bagging the wing between layers of peel ply (lightweight nylon fabric).

A small amount of finishing epoxy was applied with a squeegee and peel ply (for hinges) was tacked in place.

1.6 ounce fiberglass cloth is used exclusively. Four widths of fiberglass cloth were tacked in place at the center section.

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Old 06-16-2013, 06:55 AM
  #157  
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Default RE: AR-6 Construction Thread

A piece of peel ply was cut large enough to cover the entire wing.

A piece of 4 mil thick tarp was cut larger than the peel ply.

The vacuum pump was tested.

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Old 06-16-2013, 07:01 AM
  #158  
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Default RE: AR-6 Construction Thread

About 1.5 ounces of finishing epoxy was mixed. I add a cap of 91% alcohol to the mix to thin it out. About half is drizzled to the top left surface. Squeegee as needed to spread out the mix. Turn the wing over and apply the remaining to the bottom left surface.

Repeat the process for the other side of the wing.

Peel ply is placed on top of the wing. The wing is then turned over and peel ply is wrapped over the remaining surface.

The wing is then laid down on the plastic tarp. Rope is then wrapped around the parameter of the wing. The vacuum pump tube and ropes are taped in place. A bead of latex caulking is spread around the outside edges of the plastic tarp as needed to seal the edges. The edges are folded over and the latex caulking is smashed to seal the edges.

The wing and bag are placed between the wing shucks. Insure the wing is lined up on the shucks. I placed a few quarts of paint on top to hold parts in place.

Turn on the pump to apply the vacuum on the wing. The finishing epoxy typically dries in about 8 to 24 hours.

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Old 06-16-2013, 04:12 PM
  #159  
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Default RE: AR-6 Construction Thread

The finishing epoxy was dry after 8 hours of 90F weather. Here are some pictures showing what the wing looks like after removal from the peel ply:

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Old 06-17-2013, 09:16 AM
  #160  
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Default RE: AR-6 Construction Thread

Scott,

Can/do you reuse your peel ply? Or is it a one time use item?

Trey Witte
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Old 06-17-2013, 07:07 PM
  #161  
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Default RE: AR-6 Construction Thread

The peel ply I'm using is basically for one time use. It's just cheap shinny nylon or nylon-polyester fabric.

Excess finishing epoxy flows through fabric and is on the backside of the surface.
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Old 06-19-2013, 07:32 PM
  #162  
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Default RE: AR-6 Construction Thread

The following pictures show the installation of the aileron torque rods:
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Old 06-20-2013, 05:25 PM
  #163  
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Default RE: AR-6 Construction Thread



Excess finishing epoxy is removed with a scrapper blade.

At this point the wing weighs in at 16.7 ounces.
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Old 06-21-2013, 05:17 PM
  #164  
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Default RE: AR-6 Construction Thread

The wing was taped in place. It was confirmed to be on straight and nylon bolts were installed.
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Old 06-22-2013, 08:32 AM
  #165  
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Default RE: AR-6 Construction Thread

The aileron servo dowels (3/8" diameter) are being installed in these pictures:
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Old 06-22-2013, 08:39 AM
  #166  
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Default RE: AR-6 Construction Thread

Is the dark areas around the airloins carbon ??
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Old 06-22-2013, 09:34 AM
  #167  
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Default RE: AR-6 Construction Thread

The dark area in the area of the ailerons is brown nylon fabric (peel ply).

It is between the wood and top layer of fiberglass cloth.

It will function as the hinge after the ailerons are made. A white fabric would have worked better, but this is what I had.
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Old 06-22-2013, 11:16 AM
  #168  
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Default RE: AR-6 Construction Thread

Approximately 4.5 ounces of white epoxy Klass Kote primer was mixed. This was allowed to sit about 20 minutes.

An equal volume of lacquer thinner was added to the Klass Kote. This was then sprayed on the wing with a full size air gun.

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Old 06-22-2013, 02:55 PM
  #169  
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The primer was lightly sanded with 220 grit paper used dry.

Use a tack rag to remove the dust from the surface of the wing.

The wing was then sprayed with Acrylic Enamel paint.


Later Note: If done again I would sand off more primer. I left too much on the wing and it was a little heavier than desired.

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Old 06-23-2013, 02:06 PM
  #170  
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Default RE: AR-6 Construction Thread

The wing was wet sanded (to remove dust and runs) and touched up in a couple places.

I like the disposable paint brush shown in the picture. I just touch up areas and throw away the bottle. They are 5 for about $10 at Harbor Freight.
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Old 06-24-2013, 05:12 PM
  #171  
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Default RE: AR-6 Construction Thread

The following shows how to easily mask off and paint stripes and numbers.

Vinyl stencils were purchased locally.

Gloss black Krylon spray paint works great and dries quickly. I will later follow with a coat of automotive clear coat.
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Old 06-24-2013, 08:53 PM
  #172  
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Default RE: AR-6 Construction Thread

This Man is on a Mission !!!
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Old 06-24-2013, 09:41 PM
  #173  
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Default RE: AR-6 Construction Thread

Yep another nice job Scott
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Old 06-25-2013, 05:32 AM
  #174  
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Default RE: AR-6 Construction Thread

Looks like a first heat trim flight to me Make it go!!
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Old 06-25-2013, 04:03 PM
  #175  
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Default RE: AR-6 Construction Thread

The best case is to spray clear coat tonight and finish radio installations on this model and AJ-2 on Wednesday.

I'm hoping to travel on Thursday to Goddard (Wichita) and make some test flights.
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