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Old 03-11-2016, 07:02 PM   #71
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Re: JTec Radiowave MX2 2.8m Build log


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Thanks Travis. Actually the motor box sides are 1/8" ply with a fair bit of aeration already in place LOL. The motor mount/firewall is 1/2" ply but overall I would say that the "cutty cutty" has already taken place. If you take a look at the pictures in posts #14 and #18 you'll see what I mean. The first former is 1/4" ply (but well ventilated) and the rest is 1/8" material.
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Old 03-12-2016, 03:33 AM   #72
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Re: JTec Radiowave MX2 2.8m Build log

I like having the fuel tank right over the CG and this usually means having to make some kind of tray that allows the tank to sit over the wing tube. JTec provides a nice laser cut tank tray with supports that fit snugly over the wing tube sleeve.
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Old 03-12-2016, 03:47 AM   #73
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Re: JTec Radiowave MX2 2.8m Build log

I decided to move onto prepping the wing cores for sheeting. The first step is to check the fit of the wing root to the fuselage. One wing was perfect and the other core took a few swipes of a sanding bar to snug up the fit.

I'm using a set of wing bolts and nuts from Seacraft and I also made a set of four Teflon guides for the bolts to go through the fuselage. Threaded aluminum studs like these are easy to set up but they have a potential problem - the threads can elongate the holes and cause the wing incidence to change over time. Once I've set the incidence, I'll glue in these bushing blocks and there should be no change in the incidence over many years of flying. I cut the Teflon for the bushing blocks out of some 5mm Teflon washers that I found next to the road while on a walk last year

The plywood wing roots were prepared with some plywood blocks and 1/4-20 blind nuts.
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Old 03-12-2016, 04:02 AM   #74
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Re: JTec Radiowave MX2 2.8m Build log

Your comments on the motor box make sense, and like you said, 1/8" is pretty airy anyway.

Nice job on the Teflon blocks btw. I might have to steal your idea for inner fuse cowl mounting bolts. I find sometimes they start to compress the wood too much from all the forward leverage of the cowl weight with lots of hard 3D. A foresner bit and a some Teflon washers (both I have on my parts wall) would do wonders! Thanks for the great idea.

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Old 03-12-2016, 04:10 AM   #75
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Re: JTec Radiowave MX2 2.8m Build log

I noticed while checking the fit of the phonelic guide tubes and the root rib, that the wing cores are set up with a tiny amount of dihedral! This means that each core is designed to go to a specified side of the plane. They are not marked right or left and the manual does not make any mention of this fact. The top of the wing is the side of the foam core where the open slot is facing up (where the wing tube opening was cut out). The plywood root rib is setup with pre drilled holes for the locating bolts in such a way that you could not install the wings upside down.

The first picture shows the two wing cores attached with with the wing tube inserted. The gap clearly shows the slight amount of dihedral. The second picture was taken after I flipped the wing cores over and they lay flat on the build table. The side laying on the build table in this picture will be the top of the wing.
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Old 03-12-2016, 04:28 AM   #76
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Re: JTec Radiowave MX2 2.8m Build log

I cut openings in the root of the foam cores for the plywood blocks on the root rib. I use a HD soldering gun with wire attachments I bend out of piano wire. Before gluing in the wing tube sleeves I drill a vent hole in the end of the capped tube to allow air pressure to vent. I didn't do this on my Dalton and I still have a nice vacuum popping sound everytime I pull off a wing!

Having the wing tube sleeve securely glued into the core and into the false rib, is critical and to make sure that I get lots of gorilla glue all the way around the tube, I open up some holes in the slot and slowly twist the tube into position (while keeping each glue hole full of glue. I spray some water into the foam core and onto the phonelic tube before applying the glue and it foams up nicely! A thin coat of gorilla glue is applied to the plywood root rib, misted with water and then I tape it to the core. Wax paper keeps everything separate and some weight is used while the glue sets. Not pictured, but important, is to keep the wing tube inserted in the wing tube sleeve while the gorilla glue is foaming and expanding. It is possible to deform the wing tube sleeve otherwise.
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Old 03-13-2016, 04:52 PM   #77
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Re: JTec Radiowave MX2 2.8m Build log

Inside that scary looking contraption is the turtle deck getting its coat of 1/16" balsa sheeting
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Old 03-13-2016, 11:07 PM   #78
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Re: JTec Radiowave MX2 2.8m Build log

The turtledeck come out looking good and so the next step is to cut the opening for the vertical fin. I made a pattern by molding a piece of soft solder wire around the fin in the approximate location where the t-deck goes around the fin. This was transfered to stiff paper and trimmed until it fit well. Transferred the pattern to the t-deck and cut out the opening (inside the lines) on the band saw. There was still a fair bit of file work necessary but it ended up fitting well.

The t-deck is about 3/8" too wide for the fuselage so the next trick is how to glue it to the top of the fuse while keeping it flush with the outside edge. I clamped some 1 x 3 to the side of the fuse and lined it with wax paper (so the gorilla glue foam doesn't stick to the 1 x 3). A bead of gorilla glue along the bottom foam edge was misted with some water and the piece slid into place and was taped down.
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Old 03-16-2016, 03:34 AM   #79
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Re: JTec Radiowave MX2 2.8m Build log

I ordered one 25' roll of yellow and one 25' roll of black monokote....







Booyah!!
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Old 03-16-2016, 03:57 AM   #80
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Re: JTec Radiowave MX2 2.8m Build log

I flush cut the dowel tubes that form the canopy hatch bolt recesses. The bolt heads are totally flush with the side of the fuse and if I paint them yellow they should pretty much disappear. In the second picture you can just see the g-10 'washer" at the bottom of the recess.

The 1/8 lite ply facing was glued on the front face of the turtle deck.

The "T" shaped plywood tabs are for mounting the canopy hatch. They come with the hole for the 6-32 blind nut already drilled (laser cut) but it is basically impossible to exactly match the location of this hole on the outside of the fuselage. Instead, I filled the hole with some dowel and used the bolt holes that were already drilled in the fuselage as guides to drill the matching hole in the mounting tab. A blind nut was glued into the back of the tab and some epoxy thickened with Cabisol was used to glue the tab to the plywood hatch floor.

The hatch formers were glued into place and tomorrow I'll be able to glue in the stringers and prepare for sheeting the hatch.
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