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2Cool RC Plane

Eric builds his 2Cool radio control biplane.


This is one of the more complex planes I've attempted to build. Seth built one and I've been using his to get ideas about the construction. I will be deviating from the instructions quite a bit. I purchsed the kit from Northeast Sailplanes. In fact, I purchased 2 after botching the first one. It turned out that I frequently used parts from both kits to build this single plane


The instructions call for a simple application of tape to join the wings to the ailerons. Seth had problems at these joints where the control horns were installed. I decided that I would reinforce the edges of the joint with nylon hinges. I first made a mock up to develop a technique for installing them.


Simply trace the hinge and cut out a trough. Note the masking tape on the hinge, it keeps the epoxy from freezing the hinge. I used 30 minute epoxy as much as possible because it does not yellow, and it gives me time to make adjustments. Here I use pliers to make sure the hinge is seated well during the setting of the epoxy.


Now, do this 8 times! I was originally thinking of putting 4 hinges per aileron, but decided that that many might prove too much resistance. So, I put tape between the hinges. This turned out to work quite well. The original kit called for a small diameter carbon rod to be installed in the wing for stiffness. I had some carbon strips leftover from another kit which would make for a much stiffer wing.


I taped a straight edge to the wing to allow me to make a good cut. I had to cut a thin trough in which to glue the carbon strip and devised this tool: two blades separated by the handle of another. It cut a perfect trough for the strip.


I put tape on the blade as a reference to make sure I don't cut the trough too deep. An action shot of the cutting process. It was actually quite easy after all the setup.


The trough EPP is dug out. I found the carbon strip to be a good digging tool. This was actually the second kit I had bought in my attempt to build this plane. I used the first one on which to experiment construction techniques. Here you can see some cuts.


I used a syringe to inject epoxy into the trough. It was a bit tricky getting it in, but applying it into the trough was a breeze. Gotta make sure the wing is flat while the epoxy sets!


The bottom wing! Needless to day, I've probably spent more time on the wings then most spend putting the whole thing together! Here you can see the tape which keeps the middle part of the aileron aligned with the wing. I used 3M Blemderm


The bottom of the lower part of the fuselage needs to be reinforced. Here I glue a piece in. I will glue the sides of this piece after the bottom is set so I can place it properly. This is the nose of the plane. A fiberglass piece where the motor will be mounted will be glued here. The I glue the bottom wing to the fuselage. It's very important to make the the wing is aligned properly, there is a lot of epoxy involved!


Here I glue the two halves of the upper wing together. There are two pieces of cardboard under the wings to elevate it from the table so the the epoxy around the joint does not come into contact with the table. Kenny decides to check things out!


I figure it's time to let Kenny fly. But first, some time on the simulator! Note the image on the screen. It looks like the camera caught two frames. I suppose this is his first video game! He was not so good at flying, but very good at hitting the reset button after the simulated model crashed.


The control horns for the ailerons will mount directly on the nylon hinge, but my experience with the mock up hinges has shown me that with enough force they can be pulled off. So, I epoxy a small sheet of fairly rigid plastic to cover the hinge and the area around to form a better mounting surface for the control horn. Note masking the hinge joint is critical to making sure the epoxy does not get into it. Again, I used my primitive tool making capacity to put the plastic pieces into place. Now, is the capacity primitive, or is the tool primitive? You decide :-)


Again, I weight them down to form a nice join. The plastic is actually Styrene which is meant to be used by model railroad hobbyists to make something look like metal siding! One side of the sheet is corrugated. This side is placed down and glued.
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