[akabek]

This past summer I purchased a couple of Enya engines at our club auction. I didn't have an air frame for either engine so I went on the hunt to see what was out there. While looking up pattern planes I stumbled across a thread on a Mach 8 short kit that was being offered by a by a person out in Quebec. I believe he took the plans for a Mach 1 and scaled it down to a 0.40 size air frame called the Mach 8. Attached is a drawing of what it should resemble when I am done. The fuse is a laser cut short kit with foam core wings. Although this all started because I had purchased a couple of engines I decided to go with recommend engine a Norvel AX40 - a very light engine (~11 oz) with good power (1.4 bhp) for its size and weight. I will also be adding a Novarossi tuned pipe and header. I found tricycle retracts at a swap which I will modify to fit this bird. This is all new to me but here we go.

[akabek]

The kit designer suggests starting with the wings and horizontal stab so that is what I will do. I carved out the retract and servo bays. Then I used a long drill bit to run a passage way to run the wiring to the center of the wings. I lined some of the retract bay with 1/16" balsa. For added stiffness I ran some carbon fiber a couple inches back from the leading edge. Before I start to add the sheeting I lined the retract bay with blue painters tape. There are a couple of trenches of foam I removed which I ended up refilling due to misreading the plans....noob mistake 1 and many more to come. I filled any gaps with DAP Fast 'N Final Lightweight Spackling.

[akabek]

Next I assembled the sheeting using Lepage Express quick dry glue. Rather than use epoxy to apply the sheeting I went with LePage Low Odour Contact Cement. This is water based and applies white with a little thicker consistency of milk. After applying the glue to both the foam and sheeting I waited the recommended 30-40 minutes for the glue to turn clear. I put the wing/stab in the shuck and covered 2/3 of the surface with wax paper. This allowed me to positioned the sheeting against one edge as you only get one shot to line it up right. Then using my covering iron set at 300 I applied heat along the edge. I then removed the wax paper and starting from the center and working my way out to finish sheeting the wings and stab. So far I am satisfied with the results.

[akabek]

The horizontal stab is mostly completed. I need to sand the 45 degree angles on the leading edge of the elevators. After I build the fuselage I can properly cut the elevator width to size, add the ply inner end caps and hinges.

[akabek]

Moving right along I have most of the wings completed. I will hold off gluing the wing halves together until I have the fuselage built. The ailerons and elevators are hinged. I will set aside the wings and horizontal stab and start piecing together the fuselage.

[akabek]

I went ahead and glued the first stage of the fuselage together. It just so happened I glued the engine mount upside down. I used wood glue so I carefully use a knife to cut out the parts. I cleaned up the joints and reassembled the engine mount assembly into the fuse with epoxy. The T nuts are installed, servos and the elevator push rods are in position. In hindsight I should have left the wing T nuts and drill the holes out with the wings in position.

[akabek]

A few more pics

[akabek]

I installed carbon tube for the elevator push rods. The throttle linkage is all setup. I test fit all the retracts and setup the steering linkage. I ended up buying the Sullivan 412 fuel tank. Using a Dremel I sanded the opening in F3 so I could fit a fuel line between the tank and the F3.

[akabek]

After a little more sanding the tail section is now a nicer fit.

[akabek]

The foam I was going to use just fell apart when I tried to sand it. Based on a recommendation I decided to go to Michaels and buy floral foam. It was easy to cut with a foam hot cutter and very easy to shape by sanding. After I shaped the foam I added fiberglass cloth and Eze-Kote Laminating & Finishing Resin.