Great Planes Sportster Bipe 40 Kit - GPMA0510 - Manual (Page 9)

PREPARE THE AILERONS
Cut the aileron stock (5/8 x 17-1/2 tapered stock) to
length and draw a centerline down the leading edge of the
ailerons. Mark and drill the torque rod holes. Groove the aileron
for torque rod clearance. Make right and left ailerons.
2. CUTTHE HINGE SLOTS; FINAL SAND THE AILE-
RONS
Mark and cut the hinge slots into the ailerons and
the wing trailing edge. Shape the leading edge of the ailerons
to a “V’. Temporarily install the ailerons with hinges to check
the fit. Final sand the wing tips to match the aileron contour at
neutral. Do not permanently hinge the ailerons until after they
are covered.
BUILDING THE FUSELAGE
1. PREPARE THE FUSELAGE SIDES ,
Mark the inside of the fuselage sides “right” and
“left”. Cut out part of the wing saddle area at the rear as shown
on the plan.
STOP! If you plan to install a 4-cycle engine, read and follow
the instructions on installation of 4-cycle engines at the end of
this instruction book.
L E F T
2. PREPARE THE BULKHEADS
Locate the 1/4 x 3 x 2-3/4 plywood Bulkhead #1, the
Firewall. Mark the “top” of the firewall (the bottom has a slight
angle). Mark the position of the motor mount. Mark and drill the
holes for the motor mount
4-40 screws. Put the 4-40 blind nuts
,
in positions in these holes you drilled. Temporarily place the
mount on the firewall with the screws. Cut the screws
off in
back of the firewall so they won’t get in the way of the fuel tank.
Notch a hole in Bulkhead #2 for the throttle linkage. Prepare
Bulkhead #3 by drilling holes for the outer pushrod housings.
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