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Old 01-07-2016, 11:45 AM   #21
kfoster
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Re: 43% Aerotech Edge 540


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Finished surfaces. All of the sheeting of the foam cores turned out great! No bubbling or de-lamination. Now to put all the weights back in the weight room. Boooo!
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Old 01-07-2016, 11:45 AM   #22
kfoster
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Re: 43% Aerotech Edge 540

Here are some more pics of the finished surfaces.
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Last edited by kfoster; 01-07-2016 at 11:48 AM. Reason: add pics
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Old 01-07-2016, 11:51 AM   #23
kfoster
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Re: 43% Aerotech Edge 540

My only goal was to get the lower belly sanded flush and attached to the fuse. After some extra sanding to make sure everything fit flush I started to plan out the process of attaching the belly to the fuse. First I used some CF rod to align the belly with F2 (probably overkill with the CF rod but I had some extra rod from an old foamy). I drilled some holes in F2 and then pushed the CF rod through. Then I placed the belly flush with F2, I reached through the pipe opening and pushed the rod through and into the foam of the belly. This worked great for aligning the belly with F2, there should be very little sanding needed.
Once I was sure that all lined up, I started to brush on the poly glue. I made sure I got some glue in the holes for the CF rod. You don't need a lot just a light coat. I placed the belly on the fuse and started to tape it down. When I was mocking up the glue process I found that masking tape just did not cut it so I went the way of a good quality packing tape. This worked great! Check out the pics......
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Old 01-07-2016, 11:55 AM   #24
kfoster
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Re: 43% Aerotech Edge 540

Just ran into the shop and did some more work on the elevator halves. Cut out the servo openings and added the servo mounts. I used a dremil to cut the foam, worked perfectly! I then used some alluminium rod for the anti-rotation pins. Next I am going to use my Hanar-9 incident meter to set up the incidence. I have never done this before!
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Old 01-07-2016, 11:58 AM   #25
kfoster
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Re: 43% Aerotech Edge 540

Finished setting up the incidence on the elevators. Went really well! Added some additional supports for both the anti-rotation pins and blind nuts.
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Old 01-07-2016, 01:10 PM   #26
kfoster
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Re: 43% Aerotech Edge 540

Managed to get one half done. Pre-cutting the bevel and pre-drilling the 3/16" holes for the Robart hinges before mounting them, work unbelievably well!!!!! Very accurate and a lot less work. Here are some pics with them all together. Should be enough throw?
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Old 01-07-2016, 01:21 PM   #27
kfoster
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Re: 43% Aerotech Edge 540

I finished both the elevators. Man, they turned out nice. One thing about building, you can make sure that everything under the covering is exactly the way you want it. Next is to attach the turtle deck.
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Old 01-07-2016, 01:25 PM   #28
kfoster
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Re: 43% Aerotech Edge 540

Spent a few hours capping and mounting the rudder. I wanted to make sure it was mounted perfectly so I used a number of levels and a laser level to ensure this. After the poly glue dried, I used fiber glass tape and West Epoxy to reinforce the joint between the rudder and the rudder mounting plate. I also cut about 2" deeper into the rudder and added some light ply for reinforcement. Here are some pics of the rudder so far........
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Old 01-07-2016, 01:29 PM   #29
kfoster
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Re: 43% Aerotech Edge 540

Ok here are some pics of the almost finished rudder fillets. I still want to do some more filling and sanding.
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Old 01-07-2016, 01:33 PM   #30
kfoster
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Re: 43% Aerotech Edge 540

Finished the tail! At least until it is time to finish sand before covering. I worked on mounting the cowl and canopy hatch.
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