The first project step starts from making the parts’ from the foam sheets. Firstly, each part’s template is prepared by printing the parts’ template from the Design Plans. Trim all the border of each paper page and joining them together using tape. Each part is cut according to its shape and the paper part’s template can be traced on the foam sheet. Once the part’s shape has been traced on the sheet, the foam can be cut using a utility knife with a sharp blade for a smooth and clean cut. A hobby knife can be used for cutting the narrow-shaped holes. Repeat this process for all the parts.
The second step involves in constructing the details of the parts, such as the edge bevel and the double bevel for the fold lines. The lines for the 45° edge bevel and double bevel are traced onto the foam sheet by using the similar technique as before when tracing the paper parts’ template onto the foam sheet. Use a sharp utility blade for cutting the bevels. It is recommended that the fold lines are strengthen by applying tape along the lines, so that the parts would not tear apart when it is folded to its desired shape. (Especially the 90° fold).
After all the parts have been prepared, test fit/assemble the parts and make minor adjustment to the parts if needed before proceeding to the next step.
The third step is to prepare the control surfaces (ailerons and elevator), followed by carbon tube spar installation. The ailerons are cut from the main wing parts. The 45° edge bevels are cut along the hinge lines to allow control surface motion for aileron and elevator control. The hinges of each respective control surface are constructed by using tapes. The next procedure is to prepare the narrow holes for the carbon tube spar. Follow the recommended carbon spar location on the Design Plans. Insert the carbon tube spar into the narrow holes and cover the holes using thin layer of hot glue; flush to the surface of the foam.
The fourth step is to prepare the airfoil (the main wing and the tail wing). The airfoil parts foam sheets are glued to the main wing by using a spray adhesive (foam-safe). After all the airfoil parts have been securely attached, abrasive sand papers (fine grit-size) are used for shaping and finishing the shape of the leading edge of the airfoil. Lightly and evenly sand along the leading edge to get a smooth round airfoil.
The fifth step combines the electronics to the mechanical parts to assemble the electromechanical system of the plane. Firstly, it involves in planning the mounting location of the servos and the pin horns for each respective control surfaces. Secondly, the finishing process for the main wing is conducted on this very step before assembling to the rest of the parts (the fuselage section), unless the finishing process is by spraying paint. The finishing process on this project is to cover all the parts’ surfaces with coloured- packaging tape. This is not only increase the strength of the structure, but also give a waterproof surface, as well as a smooth surface to produce the least amount of drag on the surface.
Thirdly, the servos are mounted to each location as planned using strong double-sided tape. This enables easy maintenance / replacement in the future. The servos’ horns are assembled to the pin horn with the control rods and the pushrod connectors.
Fourthly, the motor mount is constructed as instructed in the Design Plans.
Before the pre-assembled motor mount is glued to the fuselage, similar finishing process using tapes is also applied to the fuselage section.
Besides the drive system (the motor), the receiver and the ESC are also prepared and mounted in the fuselage section. Finally, a foam solid block is shaped and glued to fill the front of the nose to increase strength for any impact.
The sixth step is the final assembly process. Assemble all the remaining parts together to the main wing (the fuselage section and the vertical stabilizers).
The final step is to configure the C.O.G (Center of Gravity) of the plane. The C.O.G location is given in the Design Plans. Make sure that all the parts, mechanical and electronics (including the batteries) are mounted during C.O.G configuration process. Adjust the battery location inside the fuselage until the C.O.G is at the proper point. Additional weights can be added in order to adjust the C.O.G. After the C.O.G has been configured, it is recommended to mark the position of the battery and set the battery to that particular location for each flight. (Please note that different battery spec (weight and dimension) will alter the previous C.O.G preset; in that case a C.O.G reconfiguration process is required).
Have fun building and make sure to share the experience. Good luck !