I started with the crutch filler block custom cut for the width of a Saito .40 and realized the limited space left for a plastic clunk tank. I eliminated the bottom 1/8" side pcs. and used 1/2" tri stock instead to tie in the 1/4" top on the crutch, also used a couple pcs. of 1/2"x3/8" beam stock for braces and did away with the crutch filler aft of the 2nd bulkhead. The reason was to open up the fuel tank compt. to the max. I will be using a Sullivan 4 oz. round tank. More on that later.
I had to push the engine all the way up to the nose ring due to the ring thickness, I also wanted to get the prop away from the large cowl for better efficiency. The nose ring is 2 pcs. in the kit but came up a little short in dimension compared to the ply N/R doubler so I shimmed it 1/8". Lots of carving, sanding and contouring!!! You'll be removing over 50% of it so don't fret on weight...yet. I split the fuse up in quarters and contoured each quarter individually, that way I kept things symmetrical. Don't forget to block your corners or you'll see daylight.
The fuse sides were pre-assembled with ply doubler, stringers and 1/4" external doubler, then book-matched & checked for dimensions. This sets the accuracy of your fuse. I didn't use a jig, just a square and glass surface. I had to use a large clamp and some moisture to get the fuse glued together along with a precisely cut tail block behind the last former to straighten everything out before the aft fuse stringer s went in. I reccomend this - "triangulation", it's worth the minimal weight, if any. I moved the cockpit aft 1" for asthetics and give it a sleeker look. A custom canopy will be needed.
I decided to build the Bud Light "Super Corsair" of the 80's. A R-4360 powered Beast built from a ex-movie prop, an A-26 cowling and P-51 spinner. 8 feet was chopped from the wings but I have no intention to duplicate that! I'll just square up the tips for that look. Maybe a 3" span change? Spinner is a Hanger 9, aluminum 2 1/2", very nice quality!
Next up is a tank mount and plumbing, tail wheel and stab install.