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20041128 - allegro - 12 - elevatorcarbon
20041128-allegro-12-elevatorcarbon: Some of the scrap uni-thick CF should be 0.014" thick. Cut two 9" pieces 3/16" thick. Dry fit them between the spine/rear elevator assembly and the leading edge...
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20041128 - allegro - 13 - elevatorlayup
20041128-allegro-13-elevatorlayup: To do the layup, I made a temporary jig using scrap balsa and dots of CA on the OUTSIDE edges of the jig pieces (to ensure I didn't CA my elevator to the glass!...
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20041129 - allegro - 01 - rudderpuzzle
20041129-allegro-01-rudderpuzzle: I made a copy of the tail plan, and then cut the pieces of the rudder out to make templates. Notice that Drela specifies how to fit the pieces of the template...
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20041129 - allegro - 02 - rudderpuzzle2
20041129-allegro-02-rudderpuzzle2: Here are the pieces placed onto the balsa sheet as prescribed by the good Doctor. Works out a little tight, so be careful! 20041129-allegro-02-rudderpuzzle2: Here...
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20041129 - allegro - 03 - ruddermarks
20041129-allegro-03-ruddermarks: To scribe the templates onto the sheet, I just marked the corners with little 90-degree marks, which I would then connected with a straightedge and marker....
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20041129 - allegro - 04 - rudderscribed
20041129-allegro-04-rudderscribed: Here is the rudder plank all scribed and ready to cut. Use a SHARP, STIFF blade for cutting these, and make sure you cut at a 90 degree angle and that when cutting...
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20041201 - allegro - 01 - hingematerial
20041201-allegro-01-hingematerial: Using Drela's <a href="http://www.charlesriverrc.org/articles/construction/markdrela_clothhinges.pdf">cloth hinge plans</a>, I made some fiberglass hinge...
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20041201 - allegro - 02 - hingethickness
20041201-allegro-02-hingethickness: 5 mils was the width I calculated for my hinge material. Drela said it should be about 2-3 mils, but the weight here is negligible....
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20041201 - allegro - 03 - slidethickness
20041201-allegro-03-slidethickness: To cut the "slice" for the hinge in the rudder, I needed a long shim to slide my *new* razorblad along to cut the slice. A little under half the thickness of the...
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20041201 - allegro - 04 - rudderthickness
20041201-allegro-04-rudderthickness: Hey! This sheet of 1/4" balsa is actually 1/4"! 20041201-allegro-04-rudderthickness: Hey! This sheet of 1/4" balsa is actually 1/4"!
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20041201 - allegro - 05 - guidelines
20041201-allegro-05-guidelines: To make sure I didn't cut too deep, I put some 45-degree, 1/4" deep "guide lines" on my #11 blade. Notice also that I have tacked it to a piece of scrap balsa to use as...
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20041201 - allegro - 06 - hingeslice
20041201-allegro-06-hingeslice: Slow, successive light cuts make the best hinge slices. 20041201-allegro-06-hingeslice: Slow, successive light cuts make the best hinge slices.
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20041201 - allegro - 07 - hingeinslice
20041201-allegro-07-hingeinslice: Here's the hinge material in the slice I've created. Awesome! 20041201-allegro-07-hingeinslice: Here's the hinge material in the slice I've created. Awesome!
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20041201 - allegro - 08 - makingsandblock
20041201-allegro-08-makingsandblock: Here I am making the 20-degree sanding block to bevel the hinge area of my rudder pieces. Please note that while Dr. Drela says 20-degree bevel in <a...
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20041201 - allegro - 09 - shouldbeseventy
20041201-allegro-09-shouldbeseventy: Yea, here is my bevel sanding jig with the 20 degree piece. Oops. DON'T DO THIS. 20041201-allegro-09-shouldbeseventy: Yea, here is my bevel sanding jig with the 20...
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20041202 - allegro - 01 - 70degreeblock
20041202-allegro-01-70degreeblock: But you *should* do this, with the 20 degree block turned on it's end, making it 70 degrees. Note I've tacked my 70 degree block to a large piece of balsa....
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20041202 - allegro - 02 - rudderweight
20041202-allegro-02-rudderweight: After beveling and installing the hinge with Duco Cement, I weighed my rudder assembly. For my rudder piece w/ hinge material, I'm at 10.4 grams! The target weight on...
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20041204 - allegro - 01 - ruddersandjig
20041204-allegro-01-ruddersandjig: The rudder sanding jig. After a little math, I figured out that for the first side, I needed 1/8" shim 14" away from the "middle" of the rudder (where the taper...
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20041204 - allegro - 02 - plywoodguards
20041204-allegro-02-plywoodguards: Rather than attempting to cut 1/32" pieces of basswood, I just used 1/64" plywood strips. They bend and laminate well. The shorter piece is used to cover the curve...
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20041204 - allegro - 03 - laminatesetup
20041204-allegro-03-laminatesetup: After a dry-fit, I smeared the strips with Titebond and set them up using masking tape. 20041204-allegro-03-laminatesetup: After a dry-fit, I smeared the strips with...
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