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Dylan's Dawn Flyer (normal Size)


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I decided to do this from scratch rather than buy the laser cut and wood pack and follow the magazine build article without too much variance, hope it helps any of the new builders out there (veterans don't look too closely wink 2).

I started off by photocopying all the main components to be cut out with the intent of ironing the image onto the wood. For some reason this didn't work so I glued them on using a glue stick so the paper is removable once finished with.

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After rough cutting to singles I attacked the wood with a hand fret saw and a sanding block. I found the edges of the paper tended to roll over or tear so also pin pricked vital positions through the paper and into the wood below (just in case).

And after about 10/15 mins I had my first former finished

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So back to it and get the rest done.

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To be fair after studying the plan and making the first few parts, I really don't see too much difficulty with this build at all, even for a complete novice builder, thats obviously all credit to an excellent design from Mr Todd, certainly makes a change from the 1/4 and 1/3 scale agro I seem to be having just lately lol

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Ok, after making all the fuz formers and rib blanks, I decided not to make the actual ribs just yet and make a start on fuz construction.

The first job is to position the motor on F1 (and F1a) since its easier now than when it fitted

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Next is to mark all the former positions from the plan to the fuz side

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F1 position is determined by your motor size and position, so measure this and make the appropriate adjustment to the marked former position on the fuz side.

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Then start gluing!, I tacked mine into position with thin cyno first then used super aliphatic down the joints to wick in. Always make sure formers are square!

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F1a and F1 are bonded with titebond II to each other after I positioned F1 on the fuz side.

I decided not to fit the 6mm longerons first before the formers, but will add them after the formers have dried, this is purely personal prefference.

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Ok first boob made, I measured and fitted F1/F1a to clear FC by 2mm and this doesn't allow for clearance of the trim on the front of the cowl, which ok the trim is purely cosmetic but I'd like to get this one right for this build blog, so will take a look shortly to see what can be done. Luckily I have epoxied in the triangular stock yet so should be an easy fix.

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Decided to leave the formers where they are and pack them up using some offcuts of ply to bring the motor forward, this is going to add a little weight to the nose, but that shouldn't be a bad thing.

I have reshaped FC former to accommodate my chosen motor, this is purely to clear the prop driver

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The fuz longerons are now in situ

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And the doublers are glued in place

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The u/c bearers once dry were dry fit as is, and marked with a pen to show the shape required to make to fit the angled fuz sides. Once marked I placed them into a vice and used a block plane to remove the majority of unwanted material and dry fit again. Once happy, finish by sanding, although I have left them slightly proud to sand off in situ once glued in.

They were glued and clamped in place with epoxy.

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