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The locations for mounting holes were copied to one of the new wings.

The pictures show the measurements.

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A 3/4" hole saw was used to cut the holes for pieces of dowels.

Some tape was applied on the bottom to keep the glue from poring out of the hole.

Pieces of dowel rods were cut to fit.

Dowels were glued in place with a thick mix of finishing epoxy and micro balloons.

I set the parts out of the way to allow the glue to dry.

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The wing tip blocks were trimmed to rough shape using a saw.

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The wing ends were moistened with water and a thin bead of Gorilla Glue was applied.

Each tip was pinned and taped in place with masking tape. Insure each tip is on straight and set the wing out of the way to dry.

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The wing tips were carved until the shape follows the curve of the rest of the wing.

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The trailing edge is sanded down to the inner fiberglass sheet for a sharp edge.
Tape is applied over the landing gear blocks to protect from finishing epoxy.
Sand the wing tips to the desired shape.
Sand the balsa sheeting is to the desired smoothness.

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The location of the aileron hinge was marked with an ink pen. This is based upon a 1 1/4" wide aileron.

Pieces of taffeta or nylon polyester (fabric) type blend were cut out with scissors.

The hinge surface (wood) was stuck with an exacto knife multiple times. This helps to improve the glue joint of the hinge.

A thin layer of finishing epoxy was applied and smoothed out with a squeegee.

The fabric was laid on the top of the finishing epoxy and smoothed as needed.

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A layer of 1.6 ounce fiberglass cloth was tacked to the wing.

An extra layer of cloth was applied on the wing tip.

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Five* more layers of 1.6 ounce cloth were applied at the wing center section.

They start at 14" wide and drop down to 7" wide.

These provide that extra layer of protection and keep the wing from folding.

*Note: Five was probably overkill. I will drop down to 4 layers on future models

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I mixed 1.5 ounces of finishing epoxy and added a small amount of 91% rubbing alcohol (about a cap full) to the mix.

This is drizzled on and then spread with a squeegee.

The other side is done the same way.

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A piece of peel ply (taffeta or nylon polyester blend) was wrapped around the wing and then placed in the homemade vacuum bag.

The bag is made from 4 mil thick plastic and is sealed with caulking. A piece of rope is placed at the back and a layer of paper towels are placed on top.

The plastic is folded over and the caulking closes the bag.

My vacuum pump pulls about 6" of Hg and then shuts off.

It was cold outside so an electric blanket was placed over the wing and insures the epoxy is warm enough to dry.

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The peel ply was removed from the wing and the edges were sanded to trim them to shape.

The surface of the wing was lightly sanded with 220 grit sandpaper on a sanding block.

The wing is strong and ready for the next steps.

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This morning I glassed a second wing. The details are covered in earlier posts.

It was cool out in the garage so an electric blanket was placed over the parts to insure the temperature was warm enough for the finishing epoxy to dry.

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The wing was removed from the peel ply and sanded to trim the edges and smooth the surface.

I now have 2 Ashley wings.

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I began making some rough cut horizontal stabilizers out of 1/4" thick balsa.

Sheets were glued together with medium CA.

I stacked 4 sheets together and cut them out with my saw.

Each is approximately 16" and construction will continue in the next few panes.

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The tail surface has 1/64" plywood pieces inserted into the wood.

These were traced and cut about 1/4" wide.

A slotting tool was used to cut a slot into the edges.

The plywood pieces were inserted into the slot.

Some thin CA was applied at the joint to hold parts in place.

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Some reference lines were marked on the trailing edge and leading edge of each tail.

A very coarse sanding block was used to shape the surface to a rough airfoil shape.

I followed with a lighter grade sandpaper to smooth each tail surface.

This process was continued until each tail surface was shaped.

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A knife was used to poke some small holes around the future hinge line.

Pieces of peel ply (polyester or nylon fabric) were cut oversize to go over the top and bottom of each tail surface.

Finishing epoxy was applied and the peel ply was laid on top.

I applied two layers of 1.6 ounce fiberglass cloth on next. This was followed with finishing epoxy.

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The horizontal tails were placed on a layer of peel ply. The peel ply was also applied to the other side.

Sections of paper towel were placed over the parts and allows vacuum to flow.

The vent tube and piece of rope were set in place.

Caulking was applied around the edges and is used to make a vacuum bag.

My vacuum pump was turned on and the plastic is pulled down as seen.

It was cold outside so I placed an electric blanket over the parts to insure that the epoxy would dry.

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Initially I cut off the section of plastic tarp that contained the caulking.

I followed by carefully pulling the fabric apart to release the stabilizers.

The last picture shows a piece of used peel ply. The excess epoxy is wicked off the surface into the fabric and helps to keep the weight down.

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A sanding block was used to trim the surfaces of the horizontal tail surfaces.

I followed with coarse and then fine sanding of the surfaces.

Here are my 4 horizontal tail surfaces.

Each weighs about 2 ounces at this point. This is just a reference point as I had to add tail weight to get the previous models to balance.

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This step is very important. Make sure to wash any residual release agent off the fiberglass parts using soap and water.

After they were rinsed they were set out of the way to dry.

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The wing was aligned and taped in place.

Small holes were drilled to identify where to locate the wing hold-down blocks.

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Excess material was trimmed from the wing saddle to allow access to servos.

I cut 1" squares from pieces of 1/4" thick plywood. These were later glued under the small holes.

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The wing was reattached to the fuselage with tape.

Holes were drilled and tapped for the wing mounting screws. Metal ones are used now to allow for future wing potting.

The other fuselage was done the same way.