RE: Extra Extra V2 - Build thread
On to the wing...It's pretty straight forward. BE CAREFUL TO LEAVE ALL SPARS AND WING TUBE SOCKETS OVERHANGING RIB #1 (inside of the wing). THIS IS NECESSARY FOR INSTALLATION OF THE WING ROOT DOUBLER. Now put the lower spar over the plan locations square up and pin in place. Then put the ribs in place square them up (balsa support blocks as shown are useful for this), and pin in place. Install the upper spar using a square (as shown) to make sure the ribs are perpendicular to the build surface. With everything checked for position, fit, and square gently pull the bottom spar upward into position and glue in place with thin CA at each rib position. Repeat on the top spar pushing it gently downward into the ribs. Next install and glue the leading edge making sure to check again for square and straightness of the ribs. After this is complete then install the top front stringers and glue in place with thin CA.
Next install the trailing edge again checking for square and straightness of the ribs. Glue in place with thin CA. Now is the time for the wing tube socket prep and installation. First cut the wing tube socket about 3/8" or so longer than shown on the plan. This will allow you a little extra tube socket beyond the third rib (you only need at most a 1/4" beyond this rib) and a little extra in the inside of the wing that will be sanded flush with the inside root doubler). Next drill a hole in one end of the tube socket that fits a round toothpick. Cut and glue in the toothpick and sand flush with the outside of the tube. Be careful not to sand too much off the tube but make sure the toothpick is not proud of the surface. This feature provides a stop/travel limit so the wing tube can't go too far into the wing during assembly and flight.
Next install the wing tube. First locate the plywood doughnut doublers and install as you slide the tube in the wing. When you install the shear webbing on the main spars (installed after this step) you will need to notch the shear webbing around these doughnut doublers. As the tube passes through each rib slide the plywood wing tube dough nut doublers on the tube. Once you are satisfied with the fit of the wing tube socket (making sure it overhangs/sticks out past rib #1) glue in and the doublers in place with thin CA.
Next install and glue in the shear webbing with the balsa sheet grain running vertically. Using balsa scraps under the sheeting will save you some sanding time on the bottom of the wing (see picture). As you install the balsa shear webbing notch it where the plywood dough nut doublers touch. The pictures show in only going out to the end of the wing tube (which is working well now) but I would recommend going on out to the wing tip (reduces a little potential flex in the wing tip). Slightly dampen the shear webbing behind the wing tube and add a little poly glue such that it will bond the wing tube to the shear webbing. Finally install the trailing edge sheeting. At this point you can slightly taper the trailing edge if you wish but I found it wasn't necessary either visually or functionally if you use thick CA (or poly, see side view picture). I used 1 1/2" wide 1/16" sheeting here. If you are going with the larger engine ranges I would probably change this to 2" sheeting. I also used a straight edge and weights to make sure the sheeting stayed down on the ribs. Next install the L.E. sheeting and rib cap sheeting. Again, leave a little overhang on the inside of the wing. Now install the inside root sheeting between rib #1 and rib #1. Again, leave a little overhang on the inside of the wing.
Next, remove the wing from the table and install the wing root doubler (has the tab). MAKE SURE WHEN YOU GLUE THE R1 DOUBLER ON THIS WING YOU ORIENT IT TO MAKE A OPPOSITE SIDE WING!
Look at the tabs, match them to the fuse pattern, and make sure you glue it on accordingly (two tabs are on the top side of the wing, pictures show an earlier version wing that only has 1 top tab). Once your happy with the fit glue it in place. Finally, turn the wing over and install the bottom side leading edge, trailing edge, and rib cap sheeting. Sand the ends flush and install the wing tip doubler. Sand the leading edge to shape. Templates are provided (if you want to use them as a guide) for the inside, middle, and outside rib leading edge profiles. Install the servo rails and tray (many options here are possible, see photos for how I did mine). Install and glue the trailing edge tri-stock in place.
Repeat for the other wing. Install any hatches you may wish to use. On my planes all I install is a balsa doubler to the inside of the root sheeting for the charge jack/switch as there is easy access to the radio gear from the inside edge of the wing.