Great Planes Giant Aeromaster Kit - GPMA0502 - Manual (Page 17)

D D 3. Use 6-minute epoxy to glue the 1/4" x 3/8" x
3-3/4" hardwood hatch blocks into the notches in ribs R-
5B and R-PB. A f t e r the epoxy has cured, cut hatch
guides from 1/4" x 1/4" x 30" balsa stick. The guides fit
between the hatch blocks and are flush with the top of rib
R-5B and R-PB. Glue in place with thin CA.
D D 4. Fit a 3/32" x 3" x 36" balsa sheet to the bottom of
the wing panel by first sanding a bevel on the front edge
of the sheet so it matches the leading edge of the wing.
Install the bottom LE sheet following the same procedure
used to install the top LE sheet.
D D 5. From the 3/32" x 3" x 36" balsa sheet leftover
from the top TE, sheet the bottom TE from rib R-1B to R-5
following the same procedure.
D D 6. Glue a 3/32" x 3/8" x 30" balsa cap strip on the
bottom of rib R-6. The cap strip should be flush with the
outside of the rib. Use the left over cap strip to sheet the
aft balsa spar from rib R-5 to R-6. The cap strip should be
flush with the front of the aft balsa spar.
D D 7. Use a 3/32" x 3" x 30" balsa sheet to sheet the
center of the wing panel between the LE and TE sheets.
There may be a slight gap between the sheets. Use thick
CA to fill the gap, wipe off the excess then spray the area
with accelerator to harden the joint.
D D 9. Use medium CA to glue 3/32" balsa cap strips to
the ribs at the side of the aileron servo hatch. From a
3/32" x 3" x 24" balsa sheet, fill the gap between the hatch
and the LE sheet and the hatch and the TE sheet. Leave
a 1/32" gap around the hatch to allow for the thickness of
the covering. Save the leftover sheet for use around the
hatch on the other wing panels.
D D 10. From the 3/32" x 3/8" x 30" balsa sticks, cut cap
strips for the remaining ribs. Use medium CA to glue them
to the bottom of the ribs.
D D 1. Use a razor saw and sanding bar with 150-grit
sandpaper to trim the bottom sheeting flush with rib R-1B.
Also, sand the sheeting in the aileron bay flush with the
aft balsa spars and the balsa rib caps.
D D 8. Center the die-cut 1/16" birch ply aileron servo
hatch over the opening for the aileron servo. Tape the
hatch in place and drill six 1/16" pilot holes at the punch
marks on the aileron hatch and into the hatch blocks.
Remove the hatch and place a drop of thin CA in each
hole in the hatch block. Wipe off the excess CA. Enlarge
the holes to 1/8". Reinstall the hatch. Secure the hatch
to the hatch blocks with six #2 x 3/8" flat head
screws (SCRW024).
D D 2. From the 5/16" x 15/16" x 18" balsa stick make a
sub TE to fit between the rib caps, against the aft balsa
spars. Glue the sub TE centered on the aft balsa spars
and rib caps. Use a sanding bar to sand the edges of the
sub TE flush the the wing sheeting.
D D 3. Use medium CA to glue the die-cut 1/8" balsa
wing tip perpendicular to rib R-6. Glue the die-cut 1/8"
balsa wing tip formers to the top and bottom of the wing
tip. Sand the tip of the formers flush with rib R-6.
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