40% Extra 300 Construction by-the-numbers
Several have asked for this kind of "by the numbers" thread for building the Extra 300- to supplement the PAK instruction booklet.
After reading the instructions several times through, construction started.
With the front bulkhead on the 300 now full size one uses the edge of a table to get the engine compartment aligned while gluing. I used the wood glue for construction of the box. Several clamps in place.
Al, forgive me. While visiting my father two weekends ago, we did some engineering. Three engineers around the table talking about statics. My sister came down and gave us her input. We are all EE's but still remember our statics enough to give it a shot. The results are 1/4 lb off of the engine box sides. Holed drilled then a band saw to take out the triangles and center area of the box sides. This was carefully done. The model was tested somewhat in the prototype, which had equal amounts of material in the front- wing tube mount area as this new one.
The fuselage sides were assembled per instructions The 1x1x72 inch aluminum triangles were purchased at Lowe's. The fuselages were joined and doubler added. A scrap 3/8 inch piece was spaced for top and bottom of the fuselage joining point. The 3/8 squares glued on the tops and bottoms with mostly wood glue, skipping about an inch every 6 to 8 inches and putting thick CA at those spots. THis allowed construction without delay of waiting for the wood glue to set.
Finally the vertical stringers were glued in with 3/8 inch square pieces, and the rear doubler glued into place.