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Ziroli 92" p-47 build thread

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Old 05-26-2017, 03:43 AM
  #101
samparfitt
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Calil,
thanks.
==================
Wing LE.
Ripped some large stock balsa into a LE for the wing.
I actually thought I could drill out the holes, perfectly spaced, and place the LE over the guns: That delusion was quickly dispelled and I just cut each LE piece for each gun and glued it in place. Will be much easier to fill in LE cuts versus enlarged gun holes. After removing the screwed in guns, started to plane down the LE to conform to the wing.
Some local neighborhood kids came over to 'help'.
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Old 05-26-2017, 07:00 AM
  #102
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Wing LE (cont)

The balsa used for the LE was extremely hard so I switched from a small modeling hand planer to my woodworking power planers and a Fein oscillating sander: It still took about 3 hours to get the LE close to where it should be.
Some masking tape laid along the wing's sheeting to protect it in case I get careless when sanding the LE.
Some 100 grit wrapped around a paint stick finished the last sanding.
I found it much easier to drill/tap the wing to the fuse before adding the LE: there was a 1/4" to 7/16" gap up front for 'wiggle room' while attaching the wing. I then knew how much of the LE had to be trimmed after gluing the LE to the wing.
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Old 05-26-2017, 01:54 PM
  #103
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Wing tips.
Cut my last remaining balsa block stock from WW II surplus for the wing tips.
Another couple hours sanding them down to the correct profile: it must of been a lot of work building those old kits that gave you lots of blocks to carve and shape!
Finally looking like a P-47 wing.
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Old 05-28-2017, 09:26 AM
  #104
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Moving surface gaps.
Used G-10 to fill in flap and aileron to wing TE gaps. Still have to do the elevators.
Had to change the blade allot for multiple cuts through the G-10.
220 grit sandpaper to rough up the sides and some CA to secure it.

Defects fill in:
Used easy sand two part auto body filler to fill in defects before glassing.
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Old 05-29-2017, 07:56 PM
  #105
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Looking good Sam!
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Old 05-30-2017, 01:59 PM
  #106
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Thanks, ragtop,
===========
Hinging tail surfaces:
The LE of the elevators and rudder were rounded over.
Used robarts large pin and pocket hinges on the elevators and rudder. Everything is modular for ease of glassing, painting, maintenance.
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Old 06-15-2017, 01:36 PM
  #107
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Horizontal stab (cont)
Cut some 1/64" thick by 5/8" wide ply to cover the gap to the elevators.
Initially, was going with an 85 engine but probably will get the DLE-120 so I can swing a 4 blade prop. It may be a little wide by a 1/4" so either some 'bubbles' an the cowl or cut the cowl in half and widen it.
With flyins and PM, time can be a premium on building.
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Old 06-16-2017, 09:57 AM
  #108
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Glassing.
First picture shows the 'tools of the trade'.
I'm using Ziroli's 1 0z FG cloth on the wings.
Normally, I would do the whole wing with one piece of cloth but, with only 1 roll left in my stock, I went the economy way and cut enough to do the out wing section with the 3' wide FG cloth.
A bondo applicator works well for me in getting a thin layer of resin over the cloth.
After the resin dried, the excess cloth around the bottom edges were sanded off.
I put some masking tape over the gun threads to keep stray finishing resin from getting on them.
Next, the center section was covered.

Fuse:
Some more 'easy sand' around the base of the vertical fin.

Vertical fin:
CA'ed some 1/64" thick ply along the trailing edge of the fin.
I'm using the ply over the G-10 as the ply is more flexible covering the rounded edges of the tips of the fin and stab.
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Old 06-16-2017, 02:35 PM
  #109
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Main wing fillet.
The plans have a 1/32" ply for the bottom of the fillet that contacts the wing. I've always had trouble getting the ply to lay flat on the wing due to stress from the fuse pushing on the ply. This time, I cut some 1/64" thick ply by 1/2" wide and stuck it under the original ply and taped it to the wing: There is no stress on the 1/64" thick ply so it lays nice and flat along the wing.
I used some thick CA to secure the 1/64" thick ply to the 1/32" thick ply. Some thick CA was also applied along the fuse sheeting where it contacts the 1/32" thick ply.
Some triangle stock was then thick CA'ed to the inside corner of the fuse to ply fillet.
Finally, some easy sand was applied to smooth over the fillet.
Some more work needs to be done but this gave a nice smooth transition from the fillet to the wing without any large gaps.
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Old 06-19-2017, 06:37 AM
  #110
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Glassing (cont)
Glassed the bottom of the wing.

Nav lights.
Some scrap plastic from existing canopies to make the covers with the help of a heat gun.

Main wing fillet (cont)
Put the flaps on the wing to finish up the back part of the wing fillet.
A small ply former cut and glued in to hold the ply flat against the flap, some triangle balsa to fill in the space and, finally, easy sand to fill in the fillet shape.
Nice doing the sanding, outside.
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Last edited by samparfitt; 06-19-2017 at 06:43 AM.
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Old 06-19-2017, 04:09 PM
  #111
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Glassing (cont)
Using only the 3' width of the FG cloth, it's taking longer to glass parts but, in the warm weather, the resin is dry enough after about 2 hours, to add more cloth to the parts. Only the other side of the fin and part of the front side of the fuse is left. The bondo applicator works well in distributing and removing excess resin.
Stab and all moving surfaces still must be done.
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