Here we go. It's crunch time, time to join the wing halves together. This is an area where you will first want to read all the way through the instructions so you know exactly what you will be doing.

Before we get going on actually gluing the wing halves together I want to stop and take a minute for another point that I disagree with the instructions. The instructions that come with the plane will tell you to glue the 2 wing halves together with thin CA, and using medium and thick CA to fill in any gaps. I am completely and totally against using CA to join wing halves. This goes against everything I have ever been taught when building airplanes. I am not going to use CA to join these wing halves together. Every wing I have ever build the wing halves were joined using 30 minute epoxy. I don't plan on changing the way I build a wing now. This is a critical joint in the structure of the wing so we want it to be as strong as possible, and that means we will use epoxy to join the wing halves.

Ok, I'll climb off of my soap box now.

We are going to be using 30 minute epoxy to join the two wing halves. It gives a longer working time (extra time to get all the parts together) than 5 minute epoxy and it is stronger than 5 minute epoxy. Before we mix any epoxy you will want to “rehearse” assembling the wing. This may sound a bit odd, but this is crucial to doing a good job on this step. When you are working with epoxy you will have a limited working time before the epoxy “sets”. Using 30 minute epoxy will give you plenty of time to get everything together, but you don't want any “surprises” to pop up when the clock is ticking. So now is the time to practice how you are going to put this together, all the way from applying the epoxy to clamping your work to how you will set it on the building board for the epoxy to set. Make sure you have a piece of wax paper or whatever you use to cover you work area with so that the wing won't stick to the building board from any stray epoxy.

Ok, take a deep breath and here we go joining the wing halves. First of all, mix more epoxy than you think you will need. You say you don't want to waste epoxy? Remember, the clock is ticking as soon as you start. Do you want to stop and have to mix more epoxy while the clock is ticking? I thought not!! I used an epoxy brush to apply the epoxy for this. It gives you more control as to where the epoxy is going than a mixing stick does. Start off by “painting” the inside of the wing panel where the dihedral braces will go (picture #1 & #2). Put epoxy on both sides of the main spar and then push the dihedral braces into place in the first wing half. Once the braces are in place put the epoxy on the inside of the second wing half where the dihedral braces will go. Set that down for a moment and apply the epoxy onto BOTH of the W1 ribs (picture #3). Now that you have epoxy on all of the surfaces that will mate, slide the wing halves together (picture #4). Yes the clock is ticking before the epoxy sets, but don't rush to the point that you make mistakes, you have plenty of time to get it all together (that's why you practiced putting together). Once you have it all lined up start putting your clamps on. You will want to make sure you clamp the dihedral braces to the spars. Also clamp together the two W1 ribs. Use as many clamps as you can get into the work area (pictures #5-#10). Double check that everything is aligned and then set the work aside. Don't touch it again until the epoxy has set. Give it plenty of time and be patient.

Pictures #11 & #12 show what the area should look like after the epoxy is dry and all the clamps are removed.

There we go. First major huge hurdle is completed. The wing halves are joined. Give yourself a pat on the back. That wasn't as hard as you thought it would be was it?

Pictures
1. “Painting” the spars with epoxy.
2. Applying epoxy to the other side of the spar.
3. Applying epoxy to one W1 rib
4. Joining the 2 wings halves
5. Firmly clamping the 2 halves together
6. Firmly clamping the 2 halves together
7. Firmly clamping the 2 halves together
8. Firmly clamping the 2 halves together
9. Firmly clamping the 2 halves together
10. Note the plastic sheeting under the wing to keep the epoxy from sticking to the work area.
11. The dihedral braces after the epoxy has dried and the clamps removed.
12. Top view of the joined areas.

Until next time

Ken