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The following information details the work that will be
completed on your project:
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Foam wings are sheeted with West Systems epoxy, with
strains of carbon fiber run full span of the cores. Two applications are laminated on the upper, and two on the
lower of each main wing core.
Wings without supplied spars will have the spars built as follow;
laminate and sandwich 1/8 ply with carbon fiber, until a thickness of about
Ό to ½ has been achieved. These
spars will run no less than 75% of the total span of the wing, and will be
bonded in place with West Systems Epoxy for an extremely strong hold.
In the many years of building wings, and aggressive flying, I have
never had a wing fold using this method.
Finished wings and tails are glassed with 2oz cloth and
West Systems Epoxy where applicable. This method may sound in some circles like
a lot of weight, but it actually does not pick up that much relative weight than
using .5 or .75.oz weight cloth.
The finished wings will be more resistant to hanger and transport
rash when finished this way.
Ailerons are capped with ½ balsa, and sanded to shape.
Robart giant hinges are used on ailerons and flaps, with 2 of brass
tubing placed over the end that protrudes into the wing and crimped and glued in
with 30 min epoxy and 1/32" milled fiberglass.
The sub trailing edge of wing is capped with Ό balsa,
and the upper surface has about a Ό overhang to cut down on open gap where
available.
Engine is mounted as requested, or outlined by
manufacturer. The
engine servo mounting is glassed into the fuse, and control horn rigged
to throttle arm.
All servos are mounted and rigged as requested or needed.
A Servo tray is fabricated and glassed into the fuse for strength
and durability. The servos in the
wing are laid on the side, and mounts built out of hardwood.
The servos are then secured in place with no4 button head screws, and
a ply strap that
goes across the length of the servo, with a small bead of thick Zap on the servo at the
strap to assist in hold it in place. The
Servo is completely and easily removable. We
will build two extra straps to have in your box, as a "just in case".
All control surfaces are rigged to the servos.
Unless otherwise specified, We use Robart control horns on the ailerons,
Sullivan 4/40 golden clevises
at all of the connections to servos and control surfaces.
Retracts are installed per plans, or mounts are fabricated,
and installed. Outer and inner gear
doors are installed if supplied. Fabricating
unsupplied gear doors will be quoted on a per project basis.
Where space permits, a removable mount will be fabricated
and used for the
installation of the retract valve and servo, for ease of service. I am partial
to the Robart adjustable unit.
Rudder and elevator will be built to your request, or
supplied parts. If your full scale aircraft
calls for fabric covered controls, the foam parts will be discarded, and the
surfaces will be built up out of 1/32nd ply, and balsa. Lightened by
a Dremel between ribs and covered in Solartex or other covering, and primered.
Robart giant hinges will be used, and the same technique will apply for
the elevator as the ailerons. Brass tubing will be added to the leading
protrusions of hinges crimped and secured with 30 min epoxy.
We will mount your fuel cell as close to the cg as possible,
or will mount per your request.
Aircraft c/g will be checked and balanced to plans or
requests. Some pilots like their
plans more aft whilst others prefer more nose heavy.
I will not ship any aircraft that is not with in what the plans call out
for on the c/g!
We dont plan to do any cockpit work.
There are a couple of companies that do a wonderful job on cockpit
presentations. Most notably is Planes Plus. Located at PlanesPlus.com
The above costs will include all Zap Ca, control rods,
Nyrods, 2 oz fiberglass cloth,
West System Epoxy, all required balsa and hard wood, any and all hardware
needed, masking tape, and labor to complete your project.
If requested we will check your engine operation,
additionally we will test
fly your aircraft at no extra charge. If you live locally, or within 150
miles we will assist
you through a couple of first hops with your new Warbird.
Retract fill valves, fuel refill valves, ignition on-off / kill switches and rx
on-off / charge jacks will be installed per your request of
as follows.
Retract fill valve:
mounted on the bottom of the fuse, aft of the wing
Rx on off / Charge jack:
mounted on the bottom of the fuse, aft of the wing
Ignition Switch:
mounted on the left side of the fuse, near the nose
Fuel fill:
mounted on the right side of the fuse, near the nose, low on the fuse
Air Ray Inc. takes
giant scale warbird aircraft to heart; they are a passion and wonderful re-creation of
some very exciting and wonderful aircraft.
Every aircraft is built as if it were a personal project.
Air Ray
Inc. will do all of the leg work, go buy the
wood, the glues, the hinges, epoxy, fuel tanks, extensions, primer, sand paper,
exactos, so on and so on.
You
ship us your aircraft kit, engine and
mounts, all the servos, radio gear, batteries, harness switch et al, with
the radio transmitter (if you would like us to set it up for
you), retracts and their full support, aircraft plans and any special
requests. And in about a months time from your reserved build date,
you get a heavy-iron warbird, ready to dogfight your locale. (Minus your final
paint and detailing)
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