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20050209 - allegro - 01 - tebeamgusset
20050209-allegro-01-tebeamgusset: To make the trailing-edge beam gussets, use the leftover from the trailing-edge stock that you stripped from the center trailing edge. Cut according to the plan....
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20050209 - allegro - 02 - cuttingbeamsupport
20050209-allegro-02-cuttingbeamsupport: For the beam blocking pieces, you can either use a solid piece of 1/2" x 1/2" balsa, or laminate together two pieces of 1/4" balsa, like that leftover from the...
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20050209 - allegro - 03 - beamgussets
20050209-allegro-03-beamgussets: A dry fit of the gussets all in place. 20050209-allegro-03-beamgussets: A dry fit of the gussets all in place.
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20050209 - allegro - 04 - beamoops
20050209-allegro-04-beamoops: Note here that my beam on the TE seems to have cured a little "funny". Hopefully this won't impact me greatly -- but it's kind of a bummer because it will be protruding...
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20050209 - allegro - 05 - beamnoseblock
20050209-allegro-05-beamnoseblock: Using epoxy thickened with Cabosil, butter the gussets and let lay up. I made sure that the square gussets were flush with the bottom of the spar, so that the...
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20050209 - allegro - 06 - beamribmarks
20050209-allegro-06-beamribmarks: To install the center ribs, you'll have to cut them into three different pieces to fit around the gussets. Just lay them along side the beam, and make sure that the...
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20050210 - allegro - 01 - beamribcure
20050210-allegro-01-beamribcure: Using some thickened epoxy (5 minute or thin with Cabosil), set up the center ribs along the beam. I used little hobby clamps to hold in place. These aren't critical,...
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20050210 - allegro - 02 - beamribcure2
20050210-allegro-02-beamribcure2: Don't know why I took this photo, but it looks nice and colorful :) 20050210-allegro-02-beamribcure2: Don't know why I took this photo, but it looks nice and colorful...
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20050212 - allegro - 01 - innertecure
20050212-allegro-01-innertecure: Make the inner LE piece out of 3/32" thick balsa cut to the thickness of the flat end of the ribs. Adhere with Titebond and use scraps of masking tape until cured. I...
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20050212 - allegro - 02 - endribcut
20050212-allegro-02-endribcut: Now, to adhere the end ribs. Cut them in three pieces as we have done before (with a razor saw). 20050212-allegro-02-endribcut: Now, to adhere the end ribs. Cut them in...
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20050212 - allegro - 03 - endribmarkbevel
20050212-allegro-03-endribmarkbevel: To mark the bevel needed between the end rib and the TE, I set the end rib on the plans and marked where they intersected along the length of the rib. One mark did...
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20050212 - allegro - 04 - temarkbevel
20050212-allegro-04-temarkbevel: Using my previously cut end-rib, I marked the TE. Note I did not use the plans, as I'll be having to mate it to the cut anyway! 20050212-allegro-04-temarkbevel: Using...
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20050212 - allegro - 05 - endribgussets
20050212-allegro-05-endribgussets: The end rib gussets I had made when I did the end-ribs on the mid-panels. They are made from 1/4" rib blank scrap CA'ed together to make 1/2" thick pieces. Apply...
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20050212 - allegro - 11 - microballoonepoxy
20050212-allegro-11-microballoonepoxy: While that was curing, I put on my filler cap strips on the bottom and top of the spar. These are made from 1/32" balsa strip. Apply the microballoon epoxy to...
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20050212 - allegro - 12 - fillercapcure
20050212-allegro-12-fillercapcure: To cure the filler cap, I used a straightedge and the pieces of foam I used to cure the carbon caps earlier. Bags of shot are real handy....
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20050213 - allegro - 01 - fillercapsand
20050213-allegro-01-fillercapsand: To sand the filler caps, I laid packing tape (or masking tape) across the ribs and used a sanding bar to get the filler caps flush with the ribs. Packing tape seems...
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20050213 - allegro - 02 - centerbottomsheet
20050213-allegro-02-centerbottomsheet: 20050213-allegro-02-centerbottomsheet:
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20050213 - allegro - 03 - centerbottomsheet
20050213-allegro-03-centerbottomsheet: Using the 1/16" x 3" x 36" sheet, I cut the sheeting to the rough form of bottom of the wing. Considering the relatively shallow curve of the bottom of the wing,...
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20050213 - allegro - 04 - bottomsheetdone
20050213-allegro-04-bottomsheetdone: Done and trimmed! 20050213-allegro-04-bottomsheetdone: Done and trimmed!
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20050214 - allegro - 01 - beambottomhole
20050214-allegro-01-beambottomhole: Using a piece of scrap hardwood as backing material, I drilled a hole through the bottom sheeting. 20050214-allegro-01-beambottomhole: Using a piece of scrap...
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