Dynaflite DYFA1009 - Manual (Page 18)

PREPARE THE PANELS
FOR JOINING
to decrease the height of the dihedral brace if needed
so it fits between the top and bottom spar.
LJ 1. Use your razor plane or a hobby knife to
shave the sharp corners of the leading edge of one
of the wing panels. Round and final shape the
leading edge with a bar sander and 150-grit
sandpaper according to the cross section on the
right wing panel drawing on the plan. Shape the
remaining wing panels the same way.
Note: The Piece 0' Cake is a motor glider, not a
high performance acrobatic model - it's named the
"Piece 0' Cake" after all! It is not critical that you
shape the leading edges with the greatest precision.
You probably would not notice a difference in the
flight performance of a Piece 0' Cake with an
accurately finished leading edge and a Piece 0'
Cake with a leading edge roughly carved to shape
with a hobby carving knife. This isn't to say that you
should not always strive for building accuracy and a
good finish, but don't worry if your LE's don't look
perfect. Building a straight fuselage and flat, warp
free wings are areas where you should concentrate
most of your building efforts.
U2. Use a sanding block or your 5-1/2" bar
sander and 220-grit sandpaper on all four wing
panels to remove any glue blobs and blend all the
ribs to the spars/ LE and TE.
LJ 1. Test fit a 1/16" die-cut plywood center dihedral
brace DB1-A in the left wing panel. Use a bar sander
JOIN THE INNER WING PANELS
Q 2. Test fit the dihedral brace in the other wing
panel. Without using any glue, join the panels with
the dihedral brace and the shear webs you cut
earlier, then temporarily clamp them together with
C-clamps, spring clips or clothespins. Make sure the
tops of ribs W1 and the bottom sheeting of both
wing panels align.
01 3. Test fit a 1/16" die-cut plywood forward
dihedral brace DB1-B between the W1 ribs and the
leading edges. The top of DB1-B should be 1/16"
below the LE's to accommodate the 1/16" top center
section wing sheeting that will be added later.
Q 4. After making any adjustments required so the
wing panels fit together and align, separate the wing
panels. Remove the dihedral braces and the shear
webs.
U 5. Gather a stack of books, balsa blocks or
something similar to prop up the end of one of the
wing panels 3-1/2".
LJ 6. Lay a piece of wax paper on your building
table. Mix a batch of 30-minute epoxy. Coat all the
joining surfaces with 30-minute epoxy, then join the
inner wing panels with the dihedral braces and
install the balsa shear webs. Place the wing on the
wax paper on your building table. Immediately
proceed to the next step.
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