Q-500 Racing Discuss AMA 428, AMA 424, and any other variants of Quickie 500 racing

Sheet a Q500 Wing

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Old 10-09-2015, 07:01 PM
  #1  
sahartman21
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Default Sheet a Q500 Wing

The following provide the basics to sheet a foam core wing. Kevin Matney (from Matney's Models) taught me the basics and now this information is being provided to you.

The cores shown were purchased from Don Stegall. Over the years Don has provided cores and sheeted cores for some of the popular Q500 racers.

I purchased the 10.5" x 48" by 1/16 balsa sheets from National Balsa. Contest or Light grade balsa wood is recommended.

Two sheets were joined using masking tape to make a sheet resembling a book cover.
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Old 10-09-2015, 07:07 PM
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Default Sheet a Q500 Wing

I followed by adding a 3" wide strip of 2 ounce fiberglass cloth at the top and bottom of the sheeting.

Begin by marking the location of the cloth (both top and bottom sheeting) using a marker.

Follow by lightly spraying the sheeting where the cloth will go.

Then follow by laying the cloth in place.
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Old 10-09-2015, 07:15 PM
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Default Sheet a Q500 Wing

For this model I chose to make the leading edge out of carbon fiber tow. This process makes a strong leading edge but adds about 0.3 ounce to the final weight vs. a balsa leading edge.

Two screwdrivers were used to make to jig to hold the carbon fiber tow.

Ten strands of tow (12K) to make up the leading edge.

http://www.cstsales.com/carbon_tow.html

The tow needs to fill the void between the sheets once they are folded over. The 10 strands fills an area about 1/8" diameter.
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Old 10-09-2015, 07:21 PM
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Default Sheet a Q500 Wing

I followed by providing identification marking on the cores.

I used a marker to identify the top and bottom of the core and shucks.

Additional marking was added to the edges of the cores. This makes it easier to identify when the cores are straight within the shucks.
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Old 10-09-2015, 07:29 PM
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Default Sheet a Q500 Wing

Adding waxed paper to the shucks helps to prevent them from getting stuck to the wing.

A light mist of 3M77 was applied to the shucks and the waxed paper was laid in place.
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Old 10-09-2015, 07:37 PM
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Default Sheet a Q500 Wing

The location of the carbon fiber laminate (7 thousandths) was marked on bottom wing skin and the carbon was tacked in place with 3M77 adhesive.

http://www.cstsales.com/carbon_laminates_48.html

Generally you should attempt to place the carbon fiber at the thickest location of the wing. I placed the carbon about 5" back (4 1/8" to the front of the carbon) from the leading edge of the wing.
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Old 10-09-2015, 07:46 PM
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Default Sheet a Q500 Wing

The location for the vertical carbon fiber sheer was identified by looking at one of the wing tips and identifying the center of the laminate (on bottom sheeting).

http://www.cstsales.com/carbon_laminates_48.html

This was approximately 4 1/4" back from the leading edge.

Mark the location for the carbon fiber sheer. I used a piece 18" x 1/2 x 14 thousandths.

A slot was cut using a razor saw.
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Old 10-09-2015, 07:54 PM
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Default Sheet a Q500 Wing

At this point I verified the vacuum pump still worked by plugging it in and listening for the hum.

I make vacuum bags using 4 mill thick pieces of plastic tarp. My favorite is about 36 wide and is cut longer than the wing span.

A piece of rope provides the path for the vacuum.

Caulking will later be used to seal the edge of the bag.
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Old 10-09-2015, 08:01 PM
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Default Sheet a Q500 Wing

I mixed 1 1/2 ounces of finishing epoxy for use on the vertical sheer, the leading edge, and wing sheeting.

I prefer to thin the epoxy about 10% by adding a cap of 91% alcohol. This makes it spread easier and allows you to use less on the wing.

Epoxy was spread on the vertical sheer and then it was slid in place.

Some epoxy was applied to the carbon fiber tow and it was laid on the sheeting.
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Old 10-09-2015, 08:07 PM
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Default Sheet a Q500 Wing

I had about 0.8 ounce of finishing epoxy remaining (from the original 1.5 ounces) and this was used on one wing half.

A squeegee (type used for car body work) was used to spread the epoxy to the skin. The picture is prior to spreading out the epoxy.

About 0.75 ounces of finishing epoxy was mixed for the other side and the earlier steps were repeated.
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Old 10-09-2015, 08:15 PM
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Default Sheet a Q500 Wing

The bottom shuck was placed under the bottom wing sheeting.

About 1/4" of sheeting should be visible in front of the foam leading edge. This space is for the addition of the carbon fiber tow.

Once the core is properly positioned pin the core in place.
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Old 10-09-2015, 08:21 PM
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Default Sheet a Q500 Wing

The top sheeting was folded over and placed on top of the cores.

The top shuck was added and aligned as needed.

They were pined and taped in place.
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Old 10-09-2015, 08:30 PM
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Default Sheet a Q500 Wing

The package was then placed on the plastic tarp.

A piece of rope was located at the back of the cores. The rope provides the path for the vacuum.

Latex caulking provides the seal around the edge of the vacuum bag.

The tarp was folded over onto the caulking and edge was pressed to seal.

The vacuum pump was turned on. It is set to cycle and provide about 6" of Hg vacuum.

I always check for leaks around the caulking seals. Particularly review an area that has folds in the tarp and address accordingly.
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Old 10-10-2015, 08:05 AM
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Default Sheet a Q500 Wing

The wing was removed from the bag by cutting off the outside seal that contains caulking.

Follow by using a sanding block (with 60 grit paper) to true up the leading edge. Then round the leading edge to shape.

The trailing edge is trimmed to make the wing cord 9 7/8" wide. A metal rule and zona saw work good for this process.
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Old 10-10-2015, 08:08 AM
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Default Sheet a Q500 Wing

The rough shaped wing weighed in at 9.85 ounces at this step.

This is a good target weight for either 424 or 426 class.
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Old 08-27-2016, 07:13 AM
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Default Sheet a Q500 Wing

Four wings were sheeted using variations of this method. At least one of the wing has a balsa leading edge.

These have been in storage until recently. In the next thread it will show how add the tips, ailerons, and cover the wing with fiberglass cloth.
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Old 08-29-2016, 06:30 PM
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Four at a time one of them must be for me
looking good Scott
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Old 05-11-2019, 06:29 AM
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Originally Posted by sahartman21 View Post
Four wings were sheeted using variations of this method. At least one of the wing has a balsa leading edge.

These have been in storage until recently. In the next thread it will show how add the tips, ailerons, and cover the wing with fiberglass cloth.

great build. Do you have a link to finishing the wing?

Thanks,
Brian
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