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<DIV><FONT face=Arial size=2>When I first tried to do this on my own, I made a
jig that I fastened to the front of the bench that my drill press was mounted on
and rotated the press head to the back side of the shaft so that it overhung the
bench side and drilled the hole vertically with a spade bit and yes it worked,
but I had foam beads all over the house. They were in the kitchen, the bathroom,
I even had them in my bed ( it's amazing what my wife puts up with
).</FONT></DIV>
<DIV><FONT face=Arial size=2>Then I purchased a KISS unit from Sam Turner and
discovered his method for gluing a piece of sandpaper to the end of a 7/8ths
dia. tube. I then built an alignment jig with adjustable length feet at the
four corners so I could set the dihedral angle and that held the tube at 90
degrees to the root rib and hand drilled the hole to the depth marked on the
7/8ths tube and voila, perfect hole !</FONT></DIV>
<DIV><FONT face=Arial size=2>It was an acceptable method, but I no longer build
foamcore wings as I can achieve significantly lighter panels going built-up. I
do, however, like the sound of Lance's coring method so don't cast me in the
mold.</FONT></DIV>
<DIV><FONT face=Arial size=2>G.</FONT> </DIV>
<DIV><FONT face=Arial size=2></FONT> </DIV>
<DIV><FONT face=Arial size=2></FONT> </DIV>
<DIV><FONT face=Arial size=2></FONT> </DIV>
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<DIV style="FONT: 10pt arial">----- Original Message ----- </DIV>
<DIV
style="BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><B>From:</B>
<A title=kgamueller@rogers.com href="mailto:kgamueller@rogers.com">Karl G.
Mueller</A> </DIV>
<DIV style="FONT: 10pt arial"><B>To:</B> <A
title=nsrca-discussion@lists.nsrca.org
href="mailto:nsrca-discussion@lists.nsrca.org">NSRCA Mailing List</A> </DIV>
<DIV style="FONT: 10pt arial"><B>Sent:</B> Friday, November 09, 2007 11:03
AM</DIV>
<DIV style="FONT: 10pt arial"><B>Subject:</B> Re: [NSRCA-discussion] wing tube
sleeve hole</DIV>
<DIV><BR></DIV>
<DIV><FONT size=2>Lance, </FONT></DIV>
<DIV><FONT size=2></FONT> </DIV>
<DIV><FONT size=2>I have cut the holes for the wing tube socket with a
hot wire</FONT></DIV>
<DIV><FONT size=2>and two templates mounted to the work bench at the
proper</FONT></DIV>
<DIV><FONT size=2>height to be on center of where the tube hole should
be.</FONT></DIV>
<DIV><FONT size=2>The socket hole is cut before cutting the core
itself.</FONT></DIV>
<DIV><FONT size=2>You need to make a slot in the core where the end support of
the </FONT></DIV>
<DIV><FONT size=2>tube </FONT><FONT size=2>is going to be to insert the
template that is mounted to the bench.</FONT></DIV>
<DIV><FONT size=2>I then burn a small hole thru the center of the templates in
the</FONT></DIV>
<DIV><FONT size=2>core with a hot piece of music wire held in a small machine
vice</FONT></DIV>
<DIV><FONT size=2>that is guided along a straight edge. Then I thread the wire
for the</FONT></DIV>
<DIV><FONT size=2>cutting bow thru that hole and start cutting following the
two</FONT></DIV>
<DIV><FONT size=2>templates. Start with a low heat and try the fit. If the fit
is too tight</FONT></DIV>
<DIV><FONT size=2>just increase the voltage a little and go around the
templates again</FONT></DIV>
<DIV><FONT size=2>until you achieve the proper fit. Of course you need a
variable power</FONT></DIV>
<DIV><FONT size=2>supply. Sounds more complicated than
it </FONT><FONT size=2>really is. Now when you </FONT></DIV>
<DIV><FONT size=2>cut the core, adjust your tip template to get </FONT><FONT
size=2>the proper dihedral. Works</FONT></DIV>
<DIV><FONT size=2>for me.</FONT></DIV>
<DIV><FONT size=2></FONT> </DIV>
<DIV><FONT size=2>Karl G. Mueller<BR><A
href="mailto:kgamueller@rogers.com">kgamueller@rogers.com</A><BR></FONT></DIV>
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style="PADDING-RIGHT: 0px; PADDING-LEFT: 5px; MARGIN-LEFT: 5px; BORDER-LEFT: #000000 2px solid; MARGIN-RIGHT: 0px">
<DIV style="FONT: 10pt arial">----- Original Message ----- </DIV>
<DIV
style="BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><B>From:</B>
<A title=patterndude@tx.rr.com href="mailto:patterndude@tx.rr.com">Lance Van
Nostrand</A> </DIV>
<DIV style="FONT: 10pt arial"><B>To:</B> <A
title=nsrca-discussion@lists.nsrca.org
href="mailto:nsrca-discussion@lists.nsrca.org">NSRCA Mailing List</A> </DIV>
<DIV style="FONT: 10pt arial"><B>Sent:</B> Thursday, November 08, 2007 10:46
PM</DIV>
<DIV style="FONT: 10pt arial"><B>Subject:</B> Re: [NSRCA-discussion] wing
tube sleeve hole</DIV>
<DIV><BR></DIV>
<DIV><FONT face=Arial size=2>That's a hard one, Mike. Both Terry and I
use a similar method. We had a machine shop make a jig for the
cutter. The cutter is a length of 7/8" wing tube with a ground
sharp edge, but the jig to hold it has got to be made presicely. I
used to use a seemingly accurate jig made to the plans provided in a KFactor
several years ago, but my results were not good enough. </FONT></DIV>
<DIV><FONT face=Arial size=2>--Lance</FONT></DIV>
<DIV> </DIV>
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style="PADDING-RIGHT: 0px; PADDING-LEFT: 5px; MARGIN-LEFT: 5px; BORDER-LEFT: #000000 2px solid; MARGIN-RIGHT: 0px">
<DIV style="FONT: 10pt arial">----- Original Message ----- </DIV>
<DIV
style="BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><B>From:</B>
<A title=mgmiller54@comcast.net href="mailto:mgmiller54@comcast.net">Mike
Miller</A> </DIV>
<DIV style="FONT: 10pt arial"><B>To:</B> <A
title=nsrca-discussion@lists.nsrca.org
href="mailto:nsrca-discussion@lists.nsrca.org">nsrca-discussion@lists.nsrca.org</A>
</DIV>
<DIV style="FONT: 10pt arial"><B>Sent:</B> Thursday, November 08, 2007
7:08 PM</DIV>
<DIV style="FONT: 10pt arial"><B>Subject:</B> [NSRCA-discussion] wing tube
sleeve hole</DIV>
<DIV><BR></DIV>
<DIV>
<DIV>
<DIV><FONT face="Arial, Helvetica, sans-serif" size=4></FONT> </DIV>
<DIV><A href="http://www.mackrc.net/patternwings2/index.htm"
target=_blank><FONT
face="Arial, Helvetica, sans-serif">http://www.mackrc.net/patternwings2/index.htm</FONT></A><BR><BR><A
href="http://www.nextcraft.com/foamwingsandparts.html" target=_blank><FONT
face="Arial, Helvetica, sans-serif">http://www.nextcraft.com/foamwingsandparts.html</FONT></A></DIV>
<DIV><FONT face="Arial, Helvetica, sans-serif"></FONT> </DIV>
<DIV><FONT face="Arial, Helvetica, sans-serif">Terry Brox's web site on
balsa skinned wings is very good and does show the drilling of the
servo lead hole with a tube and by hand. <BR><BR>Their is some great
information on these sites on building foam core wings. But a
very important part of a plug in wing would be the wing tube
sleeve hole in the core, to be straight and parallel to the desired
line centered and at the right angle to set the dihedral. Is there a site
that explains or shows the process of set up and drilling of this
hole? If this step is not perfect looks to me like the wing is dead no
matter how good the skinning process is.</FONT></DIV>
<DIV><FONT face="Arial, Helvetica, sans-serif">Thanks in
advance</FONT></DIV>
<DIV><FONT
face="Arial, Helvetica, sans-serif"><BR>Mike</FONT></DIV></DIV></DIV>
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