Well, mostly pics, but I will give measurements as required. Lets start with a list of materials:

8 yardsticks (spar)
1 4X8 sheet of 4 mil coro, color of your choice.
1 8 oz bottle of Elmer’s probond polyurethane glue (home depot)
Small bottle of CA
Lots of clamps
Two 2inch X 3 foot X 3/16” thick balsa stock
One 3 inch X 4 foot X 3/16” thick balsa stock
Wood glue or epoxy
Woodpecker tool
Lots of clamps
A square foot or so chunk of aircraft (not ‘light’) ply ¼ inch thick (firewall, wing block, landing gear block, reinforcement)
Misc. hardwood.
Chunk of 2" (or 1" would work) pink foam, approx 3"X6"

A FEW THINGS TO KEEP IN MIND DURING CONSTRUCTION:

1: Polyurethane glue takes about 4 hours to set up in 70-80 degree temps. It takes longer in colder weather, and you always need to mist with water for expansion, and faster curing times.

2: A dremel works great for grinding flutes flat. Just use a slow speed, and don't stay in one place very long. Heat will build, and melt the coroplast. Go over the entire area to be grinded; making nice, even motions with the tool.

3: A ball point pen works good for drawing your templates. Iso alcohol can be used to erase pen marks.

4: Whenever you need to fold coroplast on itself, it's helpful to remove the inside flutes on the fold line. How many flutes depends on the coroplast. I have 4 mil coroplast that varies greatly in the width of the flutes. So use your own discretion, it should fold very easily, and not crush or kink.

5: A utility knife and steel ruler clamped to the cutting surface helps cut coroplast (especially going across flutes). Press hard, hard enough to where it doesn't even feel like the coro is there. You should be digging into your work surface slightly, so use a work surface you don't mind cutting up.


Let's start on the wing first. The wing needs to be completed before you start on the major fuselage stuff. This is not a weekend project. Since I use poly glue for nearly all of my coro to coro and coro to wood joints, it takes some time for the glue to set up. Most guys should be able to get her darn near completed in a weekend, and week of evenings. Plan on roughly 30 hours to complete.

Take two yardsticks, and rip 1/4 inch off length-wise. These 1/4" pieces need to be glued to the top of two other yardsticks, giving you two 36"X 1 1/4" yardsticks. These are the main spar. I put two inches of dihedral in mine, but it's really up to you how much dihedral you put in. After you sand or cut each main spar yardstick on the end for dihedral, butt join them and glue. Take one of the yardsticks that you ripped the 1/4 inch off of, center it over the butt-joint (18" on each side of the joint) and glue it to the main spar. With two inches of dihedral, it should just fit without hanging over the main spar. This is the main spar reinforcement. Here's a cheesy drawing to show what I mean. I hope I am being clear enough.