Great Planes Gee Bee Profile 40 Kit - GPMA0485 - Manual (Page 14)

DD 5. Cut the diagonal braces from a 1/8" x 1/4" x 30"
balsa stick. Glue the braces in position.
DD 6. Remove the aileron from your building board.
Inspect all the glue joints and add CA to any joints that
don't look strong. Sand the joints flush and the entire top
and bottom surface of the aileron flat and even. Be careful
that you don't sand any area too thin.
D 7. Go back to step 2 and build the second aileron.
D 1. Place the ailerons and wing over their locations on
the plan and lightly mark the hinge locations on the TE of
the wing and LE of the aileron.
D 2. Use the leftover hinge material to make eight
3/4" x 1" aileron hinges.
D 3. Mark the centerline of the hinges on the wing's TE
and aileron's LE using the centerline method. Cut the hinge
slots and without using glue, test fit the ailerons on
the wing.
D 4. Remove the ailerons from the wing. Mark the "bevel
to" lines and sand the LE of the ailerons to a "V" as shown
on the plan.
D 1. Make 1/4" thick parts by gluing together the pairs of
die-cut 1/8" plywood, nose, front and rear guide plates
and die-cut 1/8" balsa canopy frame and fin LE. Use 6-
minute epoxy to glue the two die-cut 1/8" plywood fuselage
bodies together. Apply epoxy to one side of the fuse body.
Lightly clamp the second side to the first. If your fuse sides
are warped, you will need to twist the fuse body in the
opposite direction of the warp as the epoxy cures. This
process will take some patience, but will produce a straight
fuse body. Sand the parts as needed to match the plan.
D 2. With the waxed paper or Plan Protector positioned
over the fuse plan, pin the fuse body, nose, front and rear
guide plates, canopy frame and fin LE in position over the
plan. Cut the fuse outer frame from 1/4" x 1/4" x 30" and
1/4" x 3/8" x 30" balsa sticks. Glue the outer frame and
plywood parts together and pin it in position over the plan.
D 5. Sand a slight radius on the wing tips and the TE of
the ailerons.
D 3. Finish assembling the interior framework from the
1/4" x 1/4" and 1/4" x 3/8" balsa sticks. Glue 1/4" gussets in
the corners.
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