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Corben Super Ace Build

60 inch Scratch Built

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Phil B02/06/2019 17:59:58
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168 forum posts
161 photos

Plans by D. Tatum for 60 inch wingspan model of the 1930s classic homebuilt twin seater.

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First job was to stitch the A4 prints together.

Then trace the outlines for the fuselage sides on 3/32 medium balsa. Former positions marked.

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Phil B02/06/2019 18:16:28
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168 forum posts
161 photos

Actually this is the single seat version originally published in Popular Aviation in 1935

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Dwain Dibley.02/06/2019 19:27:05
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1265 photos

I shall be watching Phil, I built the Corben Baby Ace, from D.B.sport.

Should be an interesting build Matey.

D.D.

Phil B03/06/2019 22:34:04
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168 forum posts
161 photos

Bearers prepared

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and formers F1 to F4 roughly cut out. They need sanding to uniform shape and bearers slotted in at width of Laser 50.

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Phil B03/06/2019 22:38:30
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168 forum posts
161 photos

Dwain, what engine was in your Baby Ace?

Dwain Dibley.03/06/2019 23:36:11
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1270 forum posts
1265 photos

T'was Electric Phil. wink but .25 to .40 engines were recommended.

D.D.

Phil B07/06/2019 08:44:49
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168 forum posts
161 photos

Set of fuselage formers all cut out.

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Note error on plan for location of bearers in F2.

I have to make a new version.

Phil B07/06/2019 18:05:25
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168 forum posts
161 photos

Modified F2 former. New 1.5mm ply copy with relocated bearer cutouts sandwiched to original with fibreglass mat in between. Stronger and stiffer. img_20190607_171354.jpg

Phil B08/06/2019 12:21:14
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168 forum posts
161 photos

In case anyone else builds from this plan, watch out for another error. The width of F2 F3 and F4 is wrong as they don't allow for the thickness of the sides, so they are all 5mm too wide. F5 is correct at 90mm.the others are all 95mm. I had to take 2.5mm off each side.

Phil B10/06/2019 20:14:15
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168 forum posts
161 photos

F2, F4 and F5 glued to one side. 10mmx2.5mm balsa strips on former edges give bigger glue surface.

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The fuselage side doublers are made from 1 layer of maple veneer plus sandwiched in between, a layer of glass cloth and epoxy resin.

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Lots of wing ribs and riblets to cut (26 each). Cut by drawing round a 1mm ply rib template. Riblet shown on the plan has a different shape than the actual ribs, so I used the rib as a template.

This plan is proving unreliable.

Phil B10/06/2019 22:05:35
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168 forum posts
161 photos

Rib templates and 26 roughly cut ribs.

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Fuselage sides assembled with F2 to F5.

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Problem coming up to bring in sides to F1 and nose plate.

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Phil B12/06/2019 15:27:31
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168 forum posts
161 photos

Next to join sides at F1, inserting bearers and nose plate.

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How best to ensure the sides bend symmetrically?

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I decided to prepare the bottom plate to give the correct angles, shaped to fit F1 and F2.

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Phil B13/06/2019 11:37:43
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168 forum posts
161 photos

Bottom plate fitted and ready for gluing. Slots fit round formers. Sides give correct angles to pull in fuse sides hopefully accurately.

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First cut and fit u/c support plate from 6mm ply.

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Nice sliding fit in sides for better gluing area.

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Fitted and ready to put together rest of nose pieces.

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Dwain Dibley.13/06/2019 16:44:56
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1270 forum posts
1265 photos

She's coming along nicely, despite the plan errors Phil.

Nice and tidy too, well done so far.

D.D.

Phil B14/06/2019 10:45:33
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168 forum posts
161 photos

Bottom plate glued in. Sides pulled in. Cheek pieces glued over.

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Phil B16/06/2019 11:54:37
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168 forum posts
161 photos

Trial fit of engine bearers. Plywood template is square and sized as per Laser 50 crankcase.

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F1 and bearers glued in. Beech u/c mount cross pieces glued in.

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Ply and balsa infill under bearers, as final rounding of nose will take in the lower corners.

Front plate added.

Wing mount from 6mm ply between and over F2 to F4.

Top sides under wing mount added.

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Rear fuse pulled in and F7 glued in.

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Taking shape finally. Strangest shape fuse I've built.

NO idea at the moment how to plank the nose and build the cowl.

Phil B18/06/2019 09:40:38
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168 forum posts
161 photos

Trial fit under planking to get the contours to support skins over.

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Glued lower edge inside fuse side, hoping to Shap and glue skin to formers then plank on top.

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Phil B19/06/2019 09:42:14
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168 forum posts
161 photos

Headrest sides added and under planking fixed

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Phil B19/06/2019 23:48:17
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168 forum posts
161 photos

Shaped headrest sides.

Filled in engine bay with blue foam in prep for cowl construction.

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Cut and glued 3 laminations of maple veneer to create cockpit sides.

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Planked forward sides with 5 x 1.5 mm strips, then skinned over these with maple veneer to give the smooth surface of the full size.

Note rear fuse, from behind cockpit to tail, in the full size was fabric over stringers, so not smooth curves. I may reproduce this.

Phil B23/06/2019 20:06:25
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168 forum posts
161 photos

Shaping fuselage, cowl and beginning tail feathers.

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