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Old 03-03-2009 | 04:08 PM
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guinnb
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From: Sellersburg, IN
Default RE: Extra Extra V2 - Build thread

Once the glues are set (you should be around 1 hour to this point, maybe less) dry fit the other side to this one. You may have to fit some tabs or slots depending on how well you assembled the fuse. Don't worry here. As long as there is a good glue joint at each tab you'll be fine. The main alignment, again, comes from the dowels and tail alignment holes. Also be sure to dry fit the wing tube socket (phenolic tube).

Once you're happy with the fit (be sure it goes on and off fairly easily) add glue to the wing and tail saddles, wing tube to saddle areas (poly, foam safe CA, or epoxy), motor mounts, to the tail and wing tube areas as needed (poly glue), the formers, and assemble the side. Use a slow setting glue as you need a little time to get the glue where you need it. Be sure to keep the glue out of the front and rear anti rotation pin holes (3/8" holes on the wing centerline), the wing tube hole, and the horizontal stab slot. If you get some in there wipe it down. Now glue the wing tube socket (phenolic tube) into the wing with a foam safe glue (poly or epoxy). Be sure not to cut the tube off yet and use a square to make sure it is in proper alignment with the fuse (cut it off after the glues set).

When all is correct glue the tabs to the right side fuse. Go back and check your formers to make sure they are glued to the right side properly. After this is done the wing tube socket can be cut off with a Zona saw and sanded flush.
Next add the 3/8" x 1" (cut from sticks) square stock to the top of the canopy area (all ready precut in the sides). Next glue in the two tail wheel plywood pieces, the tail/rudder hinge cap (1" wide, 1/4" thick) balsa section, and cap the fuse with 1/16" balsa sheeting. Next glue in the two landing gear wooden dowels and sand flush to the fuse.

Now is the time to install the tail and throttle servos and wiring. There are servo trays made for this but I ended up not using them in the tail and just gluing in a ply strip on each end of the servo for the screws to bite into.

One Note: AT THIS POINT DO NOT INSTALL THE RUDDER TRI-STOCK. It will be added after you install the tail surfaces.

Final step, sit back and enjoy you're work! The fuse is complete. Just set it aside for covering and move onto the wings. My total time for the first fuse was 3 hours and that included me slowing down to take pictures. I'm confident this can be done in less than two hours. When you build it send me your times (and comments) as I'm curious to see if I'm correct.

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