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<div class=Section1>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'>Another variation on a theme – I too have gone back to
built up, but in my foam wing days….<o:p></o:p></span></p>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'>Boring a hole – this assumes your root is at right angles to
your wing mid-line. Be creative if not – shim the jig, start
with an oversize wing that will be trimmed, etc. Build a jig
consisting of: two pieces of scrap lumber (1x3 or 2x4) that have holes bored in
them big enough for your wing tube. Use a drill press, get these two dead
on aligned. Holes should be as close to the OD of your sleeve as you can easily
get, but do not have to be 100% exact. Cut a 2 small amounts off of your
sleeve, and insert into the bored holes to act as “bearings”, do
not glue yet. Find a plywood square/rectangle sized appropriately
for your wing and tube. Clamp one support to the front edge of the
plywood, one to the back edge. If you’ve got excess socket tubing,
you can just run it from front to back through the holes, instead of making “bearings”.
Insert your wing tube through the holes or into the socket, and
just like aligning a plane, work to get the tube exactly 90 deg. to the face of
the front block and base (vertical and horizontal). The longer your
base, from front to back, the better, but it all depends on how much tube and socket
materials you have available. Glue/screw the whole shebang – boards
to the base, wing socket or “bearings” to the holes, making sure
the wing tube itself will be square to the face of the front block while it all
sets up.<o:p></o:p></span></p>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'>Use: Cut about a 2-3” piece off of your wing
socket. File teeth in it, just as you would for brass tubing when boring
smaller holes in balsa. Phenolic sockets work great. You may have
to harden other materials with CA in order to get it hard enough to make
teeth. Glue the “saw” onto the end of your wing tube. Butt
the face of the front block up to the wing root, using spacers (more scrap
lumber) to get the jig face firm against the root, but allowing for clearance
between the front support and the root for the “saw”. Shim
the jig up or down to get the saw lined up exactly where you want the hole to
start. Support your wing tip as needed to provide any dihedral you might
need (if doing so, of course, make sure you start a little “high”
on the root). Clamp/weight everything down very firmly. Start
twisting your wing tube back and forth, boring into the foam with the
saw. You will have to pull it all out, and clear the saw of foam periodically,
but once started, using the existing hole to realign everything is a snap.<o:p></o:p></span></p>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'>Sure, use of scrap lumber, etc. may give some the willies due to
lack of extreme precision….so if you’ve got the capability to make
it all more precise, go for it. The concept is the same – use a
long baseline to keep everything in alignment as you drill. Use your wing
tube as the drill shaft, riding in sleeve bearings to keep tolerances
close. Use the wing sleeve as the drill bit, to get a really nice, close
fit that requires a bare minimum of glue.<o:p></o:p></span></p>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'><o:p> </o:p></span></p>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'><o:p> </o:p></span></p>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'>Ted Sander<o:p></o:p></span></p>
<p class=MsoNormal><span style='font-size:11.0pt;font-family:"Calibri","sans-serif";
color:#1F497D'><o:p> </o:p></span></p>
<div>
<div style='border:none;border-top:solid #B5C4DF 1.0pt;padding:3.0pt 0in 0in 0in'>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Tahoma","sans-serif"'>From:</span></b><span
style='font-size:10.0pt;font-family:"Tahoma","sans-serif"'>
nsrca-discussion-bounces@lists.nsrca.org
[mailto:nsrca-discussion-bounces@lists.nsrca.org] <b>On Behalf Of </b>Lance Van
Nostrand<br>
<b>Sent:</b> Friday, November 09, 2007 6:37 PM<br>
<b>To:</b> NSRCA Mailing List<br>
<b>Subject:</b> Re: [NSRCA-discussion] wing tube sleeve hole<o:p></o:p></span></p>
</div>
</div>
<p class=MsoNormal><o:p> </o:p></p>
<div>
<p class=MsoNormal><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>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.</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal> <o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>--Lance</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal> <o:p></o:p></p>
</div>
<blockquote style='border:none;border-left:solid black 1.5pt;padding:0in 0in 0in 4.0pt;
margin-left:3.75pt;margin-top:5.0pt;margin-right:0in;margin-bottom:5.0pt'>
<div>
<p class=MsoNormal><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>-----
Original Message ----- <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal style='background:#E4E4E4'><b><span style='font-size:10.0pt;
font-family:"Arial","sans-serif"'>From:</span></b><span style='font-size:10.0pt;
font-family:"Arial","sans-serif"'> <a href="mailto:kgamueller@rogers.com"
title="kgamueller@rogers.com">Karl G. Mueller</a> <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>To:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> <a
href="mailto:nsrca-discussion@lists.nsrca.org"
title="nsrca-discussion@lists.nsrca.org">NSRCA Mailing List</a> <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>Sent:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> Friday, November 09,
2007 10:03 AM<o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>Subject:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> Re:
[NSRCA-discussion] wing tube sleeve hole<o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><o:p> </o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>Lance, </span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal> <o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>I have cut the holes
for the wing tube socket with a hot wire</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>and two templates mounted to
the work bench at the proper</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>height to be on center of
where the tube hole should be.</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>The socket hole is cut before
cutting the core itself.</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>You need to make a slot in
the core where the end support of the </span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>tube is going to be to insert
the template that is mounted to the bench.</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>I then burn a small hole thru
the center of the templates in the</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>core with a hot piece of
music wire held in a small machine vice</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>that is guided along a
straight edge. Then I thread the wire for the</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>cutting bow thru that hole
and start cutting following the two</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>templates. Start with a low
heat and try the fit. If the fit is too tight</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>just increase the voltage a
little and go around the templates again</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>until you achieve the proper
fit. Of course you need a variable power</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>supply. Sounds more
complicated than it really is. Now when you </span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>cut the core, adjust your tip
template to get the proper dihedral. Works</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>for me.</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal> <o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt'>Karl G. Mueller<br>
<a href="mailto:kgamueller@rogers.com">kgamueller@rogers.com</a></span><o:p></o:p></p>
</div>
<blockquote style='border:none;border-left:solid black 1.5pt;padding:0in 0in 0in 4.0pt;
margin-left:3.75pt;margin-top:5.0pt;margin-right:0in;margin-bottom:5.0pt'>
<div>
<p class=MsoNormal><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>-----
Original Message ----- <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal style='background:#E4E4E4'><b><span style='font-size:10.0pt;
font-family:"Arial","sans-serif"'>From:</span></b><span style='font-size:10.0pt;
font-family:"Arial","sans-serif"'> <a href="mailto:patterndude@tx.rr.com"
title="patterndude@tx.rr.com">Lance Van Nostrand</a> <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>To:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> <a
href="mailto:nsrca-discussion@lists.nsrca.org"
title="nsrca-discussion@lists.nsrca.org">NSRCA Mailing List</a> <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>Sent:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> Thursday, November
08, 2007 10:46 PM<o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>Subject:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> Re:
[NSRCA-discussion] wing tube sleeve hole<o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><o:p> </o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>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. </span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>--Lance</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal> <o:p></o:p></p>
</div>
<blockquote style='border:none;border-left:solid black 1.5pt;padding:0in 0in 0in 4.0pt;
margin-left:3.75pt;margin-top:5.0pt;margin-right:0in;margin-bottom:5.0pt'>
<div>
<p class=MsoNormal><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>-----
Original Message ----- <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal style='background:#E4E4E4'><b><span style='font-size:10.0pt;
font-family:"Arial","sans-serif"'>From:</span></b><span style='font-size:10.0pt;
font-family:"Arial","sans-serif"'> <a href="mailto:mgmiller54@comcast.net"
title="mgmiller54@comcast.net">Mike Miller</a> <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>To:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> <a
href="mailto:nsrca-discussion@lists.nsrca.org"
title="nsrca-discussion@lists.nsrca.org">nsrca-discussion@lists.nsrca.org</a> <o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>Sent:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> Thursday, November
08, 2007 7:08 PM<o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Arial","sans-serif"'>Subject:</span></b><span
style='font-size:10.0pt;font-family:"Arial","sans-serif"'> [NSRCA-discussion]
wing tube sleeve hole<o:p></o:p></span></p>
</div>
<div>
<p class=MsoNormal><o:p> </o:p></p>
</div>
<div>
<div>
<div>
<p class=MsoNormal> <o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><a href="http://www.mackrc.net/patternwings2/index.htm"
target="_blank"><span style='font-family:"Arial","sans-serif"'>http://www.mackrc.net/patternwings2/index.htm</span></a><br>
<br>
<a href="http://www.nextcraft.com/foamwingsandparts.html" target="_blank"><span
style='font-family:"Arial","sans-serif"'>http://www.nextcraft.com/foamwingsandparts.html</span></a><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal> <o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-family:"Arial","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.</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-family:"Arial","sans-serif"'>Thanks in
advance</span><o:p></o:p></p>
</div>
<div>
<p class=MsoNormal><span style='font-family:"Arial","sans-serif"'><br>
Mike</span><o:p></o:p></p>
</div>
</div>
</div>
<div class=MsoNormal align=center style='text-align:center'>
<hr size=2 width="100%" align=center>
</div>
<p class=MsoNormal>_______________________________________________<br>
NSRCA-discussion mailing list<br>
NSRCA-discussion@lists.nsrca.org<br>
http://lists.nsrca.org/mailman/listinfo/nsrca-discussion<o:p></o:p></p>
</blockquote>
<div class=MsoNormal align=center style='text-align:center'>
<hr size=2 width="100%" align=center>
</div>
<p class=MsoNormal>_______________________________________________<br>
NSRCA-discussion mailing list<br>
NSRCA-discussion@lists.nsrca.org<br>
http://lists.nsrca.org/mailman/listinfo/nsrca-discussion<o:p></o:p></p>
</blockquote>
<div class=MsoNormal align=center style='text-align:center'>
<hr size=2 width="100%" align=center>
</div>
<p class=MsoNormal>_______________________________________________<br>
NSRCA-discussion mailing list<br>
NSRCA-discussion@lists.nsrca.org<br>
http://lists.nsrca.org/mailman/listinfo/nsrca-discussion<o:p></o:p></p>
</blockquote>
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