Fuse Formers

These are fairly easy. Every former except the firewall and F2 are made from 1/8" 4-6 lb balsa. you need good, stiff C grain wood for this.

First cut the formers to approximate size.

Lay the former on top of the plans, and mark a center line with a sharpie.

Now using a block sander, sand the edges until you can barely see the outline all the way around the former.

Flip the former over and transfer the center line to the other side.

using a straight edged cork back ruler, mark the notches for the stringers and cut them out. note that a few of the formers in the front have flat bottoms, they simply sit on top of the stringers at those locations.

Now cut out the centers and sand smooth.

For F-2 and the firewall, you'll need to ither cut the plans, or make a copy and cut the copy. You will use that as a template. You'll need 2 copies of F2 as the parts overlap, or you can just wing it.

Spray the back of the paper lightly with 3M 77 spray adhesive. Let dry for about a minute, then apply the F-2 templates to a piece of flat 1/8" lite ply.

Apply the firewall former to a piece of 1/8" AC ply.

Cut them both out on a scroll saw or band saw.

transfer the center lines to these as well. Transfer the trust line onto the firewall. Sand F2 to final shape and you're done with it.

For the firewall, it needs to be laminated with a piece of 1/8" 4-6 lb C grain balsa. if your building a glow version, you'll need to make a circular cut out to back up the engine mount. Make a circular hole the same size as the plywood piece in the balsa, and fit it into place. Laminate them with a thin covering of epoxy and weight down and let cure. See pics for details.

If you're building the electric version, you need to laminate it straight with a piece of 1/8" balsa, with carbon on both the outer surfaces. Use 2 ounce carbon, and you can either vacuum this down or put piece of mylar over both sides and a LOT of weight on it.

When this cures, drill the holes for your motor mount. This will vary a LOT depending on what you do here. But using a drill press and a 3/8" piece of charpened brass tubing, cut into the balsa side until you hit the ply (you'll know). At this point remove the cut out piece with a small screwdriver or whatever. then laminate in pieces of 3/8" dowel. Let this cure and then redrill.