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<DIV><FONT size=2>Lance,</FONT></DIV>
<DIV><FONT size=2></FONT> </DIV>
<DIV><FONT size=2>To get around having to burn a hole and feed the wire thru
this,</FONT></DIV>
<DIV><FONT size=2>there is away to cut the tube hole by cutting a slot going
into the tube hole </FONT></DIV>
<DIV><FONT size=2>from the top of the core.</FONT></DIV>
<DIV><FONT size=2>You can incorporate this slot on the templates and do it all
in one cut.</FONT></DIV>
<DIV><FONT size=2>The only problem is that your wire will go into the slot if
you wanted to go</FONT></DIV>
<DIV><FONT size=2>around the inside of the tube hole more then
once.</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>
<BLOCKQUOTE
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> Friday, November 09, 2007 7:37
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>Thanks Karl, this is a good idea. It
produces a hole that looks very clean. My concern is how to get the
template end that is inserted into the wing into the precise location. I
didn't used to be too concerned with this. As long as the holes in the
opposing wings were close they were good enough because when I mount the wing
tube in the fuse I would perfectly align the wings. Even if the wing
tube was tilted, it would not matter. However, now that we sell kits and
people order replacement wings, or use the wing tube itself to align with the
stab, I feel I must have a method that is repeatable to a very accurate
degree. Also, another difference from the home builder to the production
shop is time. Your method looks like it would be quick to do, but not as
sure about the setup (having to burn the initial hole and feed the
wire). I'm sure that with practice any method becomes
efficient.</FONT></DIV>
<DIV><FONT face=Arial size=2></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=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 10:03
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>
<BLOCKQUOTE
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>
<BLOCKQUOTE
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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