Q-40 Racing Discuss AMA 422 and any other variants of Quarter 40 racing

Build an Ashley MM

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Old 01-01-2016, 09:54 AM
  #26  
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A piece of 3/32" plywood was cut out and tacked on to the nose.

A couple drops of medium CA was used to tack the wood to the fiberglass.
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Old 01-01-2016, 10:00 AM
  #27  
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The engine cutout was marked and cut out like was done earlier in this thread (for the fuselage with the 1 3/4" spinner).
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Old 01-01-2016, 10:08 AM
  #28  
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The hole size on the plywood was increased to better fit the spinner.
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Old 01-01-2016, 10:12 AM
  #29  
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Some carbon tow was added at the joint.

A mixture of finishing epoxy, cabosel, and cotton flox was prepared and dabbed around the joint.

The fuselage was set out of the way to dry.
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Old 01-02-2016, 07:06 PM
  #30  
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The plywood was trimmed and shaped with a Dremel tool. A sanding block with 220 grit paper was used for the final shaping.

The last picture shows the two different nose lengths.
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Old 01-02-2016, 08:17 PM
  #31  
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Looking GOOOD !
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Old 01-03-2016, 06:23 PM
  #32  
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Jim Allen just sent approval for the shorter nosed version.

Both versions are now approved.
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Old 01-04-2016, 07:08 PM
  #33  
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Fitting the firewall (for the 2" spinner) follows the same steps as shown earlier:

  1. Make a pattern that will fit the associated area of the fuselage (front side of the firewall).
  2. Cut out a firewall from 3/8" thick plywood.
  3. Grind and sand the front of the firewall to allow it to slide in place.
  4. Continue to sand the edges as required to fit in the fuselage.
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Old 01-05-2016, 03:45 PM
  #34  
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The attachment contains sketches of the firewalls on both versions of the model.
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Old 01-09-2016, 02:44 PM
  #35  
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The firewall for this version was attached similarly to the other installation.

Here are a few pictures showing the process:
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Old 01-09-2016, 02:48 PM
  #36  
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More pictures:
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Old 01-09-2016, 02:52 PM
  #37  
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Holes were drilled for the blind nuts and the kill tube.

The kill tube was filled with Vaseline to keep epoxy out while gluing in place.
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Old 01-09-2016, 03:00 PM
  #38  
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The firewall was coated with finishing epoxy.

Some Cotton Flock was added to the remaining epoxy to thicken it.

The mix was applied to the back of the firewall joints and spread as required.

The fuselage was set inside out of the way to dry.
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Old 01-17-2016, 03:10 PM
  #39  
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Here are a few pictures of the cutting out the 1/4" thick balsa horizontal tail surfaces. I cut out three as it is generally just as easy to cut out more than one at a time.
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Old 01-24-2016, 04:21 PM
  #40  
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Some 1/4" wide by pieces of 1/64" plywood were cut into strips.

Slots were cut into the balsa sheets using my slot jig. It is made by placing an exacto blade between pieces of plywood. Parts are held together with a couple screws and nuts.

The plywood strips were placed into the slots.

Some thin CA is used to glue in the strips.

A sanding block was then used to true up the edges and remove any excess hardened CA.
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Old 01-24-2016, 04:27 PM
  #41  
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Mark the leading and trailing edge to provide a guide where to shape.

A balsa plane was initially used and it was followed with a coarse grade sanding block (60 grit).

Continue to shape until the trailing edge is relatively sharp. The leading edge should be gently rounded.

I finished with150 and 220 grit sandpaper on a sanding block.
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Old 01-24-2016, 04:30 PM
  #42  
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Two more stabs were shaped and then I began planning the placement on the peel ply (blue fabric).
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Old 01-24-2016, 04:37 PM
  #43  
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Some finishing epoxy was mixed and a piece of white fabric (nylon or polyester blend material used for dress linings) was attached to the surface.
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Old 01-24-2016, 04:39 PM
  #44  
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A layer of 1.6 ounce fiberglass cloth was applied to both sides of the stabilizer.
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Old 01-24-2016, 04:50 PM
  #45  
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The parts were placed between the layers of peel ply and placed on a piece of plastic tarp (4 mil thickness).

A vacuum tube was taped in place. Paper towels are placed over the top and serve as a bleeder cloth.

A bead of caulking was run around the edges of the plastic tarp and is used to temporarily seal the vacuum bag.

Once the edges of the bag are sealed the pump is turned on. My vacuum pump cycles and is set to pull about 6" Hg vacuum.

It was cold in my garage so an electric blanket was used to insure the finishing epoxy is warm enough to dry.

Wait at least 12 hours for the epoxy to completely dry before removing from the peel ply.
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Old 01-29-2016, 02:10 PM
  #46  
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The parts were removed from the peel ply.

I trim the edges with a sanding block.

Lightly sand the surface with sanding block and 220 grit sandpaper.
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Old 01-29-2016, 06:29 PM
  #47  
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Must be cold in TX. I was about 1 week for them to dry.
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Old 01-29-2016, 06:35 PM
  #48  
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Next was the installation of the servo tray.

I began by laying a servo beside the fuselage and marking the proposed location.

I try for 1 1/4" to 1 3/8" space between the wing and servo arms. This is to allow room for the aileron torque rods and pushrods.
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Old 01-29-2016, 06:37 PM
  #49  
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Originally Posted by Kevin Matney View Post
Must be cold in TX. I was about 1 week for them to dry.
It was dry the next day. I hadn't had a chance to work on them until now.
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Old 01-29-2016, 06:41 PM
  #50  
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Default Build an Ashley MM

Some rails were glued in place with CA and measurements were taken for the servo tray.

The tray was rough cut and verified to fit. The tray should fit without pressure on the fuselage sides.
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