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Fouga magister 1/4.5 moulded from scratch

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dirk tinck25/11/2018 22:46:01
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358 photos

Hello all,

As you see in the previous post,a friend of me,Ben,offered his help to draw the internal structure for the wings.

This will save me lots of time !He has also a home-made cnc cutter wich will come in handy ! Thanks Ben !!

dirk tinck25/11/2018 23:22:00
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211 forum posts
358 photos

20181121_225026.jpg20181121_223449.jpg20181121_215719.jpgTime to tackle the ailerons !

First draw the ailerons on the wings,cut them out and give them a round leading edge.Before closing them,i'm going to add a hinge tube in aluminium,right in the centre of the leading edge curve.To form this curve,i'm glueing two metal ribs on the sides,then sand the ailerons on a flat board with some sandpaper glued on.20181120_233403.jpg

dirk tinck25/11/2018 23:25:05
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211 forum posts
358 photos

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dirk tinck25/11/2018 23:28:16
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211 forum posts
358 photos

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dirk tinck25/11/2018 23:37:54
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211 forum posts
358 photos

Next is to put the ailerons back in place on the hinges.first clean up the sides of the opening in the wing with 2mm balsa20181124_233201.jpg

dirk tinck25/11/2018 23:43:51
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211 forum posts
358 photos

Got two peaces of hinge tube ready to glue in place in the wing.they have to be perfect in line with the aileron hinge tube20181125_202303.jpg

dirk tinck25/11/2018 23:45:21
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211 forum posts
358 photos

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dirk tinck25/11/2018 23:54:46
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211 forum posts
358 photos

To align wing and aileron i used two peaces of gfk hinge -axle.Later these will be replaced by a full ail-span axle.

With the aileron opening in the wing cut out to big,i'm going to form a hollow balsa spar to glue in just in front of the aileron.Nearly impossible to sand this right so i'm going to use two peaces triangular balsa stock 6x6 glued to a 2mm balsa base20181124_233245.jpg

dirk tinck26/11/2018 00:03:02
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211 forum posts
358 photos

The gap with the piece to fill ituser_scoped_temp_data_thumbnail1543183321260.jpg

dirk tinck26/11/2018 00:07:06
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211 forum posts
358 photos

20181125_225948.jpg20181125_225925.jpgOnly thing to do now is to glue it in place ,clean up the aileron sides to fit prfect in the wing opening20181125_225930.jpg

dirk tinck26/11/2018 00:17:17
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211 forum posts
358 photos

20181125_225948.jpgI had to use a little filler to clean up the wing just in front of the aileron.

I'm happy with this day's work and the result.Te gap between aileron(God i'm beginning to hate this word) and wing is minimal but still have some space for glassing and paint.Deflexion is possible up to 60-70 degrees both up and down without the aileron touching the wing20181125_230045.jpg !More than i need !

Devcon126/11/2018 04:52:14
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1358 forum posts
476 photos

That's very neat work and well worth the effort.. I like the idea of being able to remove them.

dirk tinck26/11/2018 23:25:33
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211 forum posts
358 photos
Thanks for your visit and Coment devcon1!In case i need to pull more then one out of the moulds,this will save a lot of time in the end.Cheers !
dirk tinck09/12/2018 12:12:06
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211 forum posts
358 photos

Hi again ,before going on with the build,let's get you up to date :

After getting the second aileron in place,it's time for the flaps !

It's pretty much the same way of work if it wasn's for the flaps being seperated by a little piece of wingangry 2

Anyway,first i'm doing them as a single flap20181130_230004.jpg

dirk tinck09/12/2018 12:22:06
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211 forum posts
358 photos

firt draw the flaps onto the wing.The flaps are way much wider on the underside than on the top-side as you can see on the scale drawing.I have to search for a compromise because the real fouga has fowler flaps (they slide backwards)I'm not going this route as it's way to much work.I'm doing them the ''easy'' way with tube hinges.20181130_225958.jpg

dirk tinck09/12/2018 12:25:56
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211 forum posts
358 photos

Got a new tool to cut the flaps out ! It really gives a clean cut ! Thanks Proxxon20181130_230732.jpg

dirk tinck09/12/2018 12:29:25
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211 forum posts
358 photos

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dirk tinck09/12/2018 12:43:31
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211 forum posts
358 photos

After cutting the flaps out of the wing,i'm putting the hinge tube in just above the flap skin,then give the flap a leading edge in a way that 1:wing and flap don't touch

2 :With the flaps up, there's no gap on the upper side

3 :With the flaps lowered ,keep the gap minimum.

As you see in the foto,i first try'd to keep the scale size of the flap but it didn't work because of the difference in thickness at the root and tip of the flap.

dirk tinck09/12/2018 12:51:40
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211 forum posts
358 photos

20181206_210710.jpg20181206_210713.jpgWith the hinges in place and a trouble-free movement of the flap it's time to make a double flap out of a single flap !

1:20181205_214707.jpg Drawing the lines on wing and flap

dirk tinck09/12/2018 13:00:15
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211 forum posts
358 photos

2 : Cutting the wing and flap for about 2cm with a 1mm disc on a disc grinder. This gives a cut aprox.2 mm wide,just enough to slide some 2mm balsa in.This will provide the stiffness for the little piece between the flaps20181206_212641.jpg20181206_211447.jpg

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