Phase 5 by Chris Foss

Here is the finished core, the root section, the tip section and the core placed over the plan

MikeSeale wrote: Chris Wild (also planning to build a Phase 5) raised a concern that it would be difficult to carve/sand two identical halves

Knowing Chris, I can imagine that has been keeping him awake at night with worry

I was keeping my involvement in this project quiet as I know I have a tendency to cause Jon to roll his eyes!

That's pretty neat Mike

Although originally planning on a sparless wing, it had been pointed out that the aileron and flap servo bays create a weak point and have decided to add a spar just in case. I tried cutting slots for the spar caps but could not get consistent results using the hot wire. So have decided to cut a vertical slice out of the wing and then rejoin it with a pre-made spar. I've gone for 1/4 x 3/16 caps and 3/16 balsa shear web which is drying overnight.

I cut the wings in half and re-joined them with the spar in place. A light pass with the sanding block levelled them with the foam (protected with masking tape.
Then cut out the servo bays prior to sheeting. I'll keep the foam blocks and cut a slice to line the floor of the bays later.
Then cut a slot for the servo wires.

That wing isn't failing Mike!

JonTappin wrote: That wing isn't failing Mike!

I hope not!
A hard point has been added to the root of the wing. Once skinned I can drill through for the wing bolt.
Skins are 1/32 balsa secured using Gorilla (polyurethane) glue. Spread it thinly using an old credit card. I find it easier to use more glue than necessary then remove the excess. When spreading you need to move slow enough for a dam of glue to build up in front of the credit card. This ensures that the wood is wet all over. The edges and corners are particularly important.
Skinned cores are then placed back in the foam off-cuts and tapes all around to make sure the leading edges and trailing edges are tightly in place.
Finally some weights are added to hold it tight until morning.

The wings came out of the skinning process and I've spent the last few days finishing off using aliphatic glue, so it takes a while between tasks.
A 1/4 inch leading edge and 1/16 hardwood trailing edge is added.
Ailerons and flaps are cut out and faced with 1/4 leading edge and 1/8 caps on each end. The wing trailing edge is also faced with 1/4

The servo bays are opened up and faced with 1/8.
Wing tips added and waiting to be carved and sanded to shape tomorrow.
Wing root sanded and ready for joining tomorrow

Looking good Mike. Servo bay Iayout I had planned for the Phase 6. One thing though - installing the servo leads. Slotting the underside?

?? Time of your posts - around midnight. :blink: