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Author Topic: shaping leading edge  (Read 3239 times)

Offline Bootlegger

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shaping leading edge
« on: July 07, 2012, 11:38:09 AM »

  Fellow's I am looking for some way's to shape a wooden leading edge that has been glued to a foam wing.
 The wing in question is set up with sheeting, false rib's and has trailing edge sheeting on it.
  I sure don't want to "gouge" the l/e sheeting when shaping the leading edge, so all help/suggestions will be appreciated.
  The wing is not completely sheeted, only the l/e, fake cap strips, and t/e..
  Thanks a lot for your ideas...
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Offline Dan Bregar

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Re: shaping leading edge
« Reply #1 on: July 07, 2012, 12:05:27 PM »
In the past I have used masking tape or other types of tape to protect the sheeting as I am grinding down the leading edge stock with #80 sand paper. Put a strip of tape or two, depending on the tape width, behind the leading edge stock onto to sheeting full length span wise.  This should protect the sheeting as you sand.  When you get the leading edge stock close to shape, you will start to sand into the tape, but the tape will be protecting the sheeting until the leading edge stock is almost perfectly flush with the sheeting. About then I change my #80 paper out to #120 or such and carefully blend any remaining extra leading edge stock into the sheeting. A nice long flat sanding block helps a lot.  Have fun.  :)
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Offline Avaiojet

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Re: shaping leading edge
« Reply #2 on: July 07, 2012, 12:10:02 PM »
Bootlegger,

A photo would be nice and helpful.

You can tape off areas not to be sanded.

Years ago I did plenty of sheeted foam wings with .375" thick LE's for R/C pattern.

Everybody did this the same way back then, each side of the foam end we would draw a center line through the airfoil, then continue the line along the LE or TE.

Just bar sand to shape. Some guys would make LE shapes with sandpaper inside them as a guide. I'd just eyeball.

I did do one LE and made a half guide. I dug it up just for the photo. Through nothing out.

Hope this helps.

What are you working on?

Charles
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Offline Brett Buck

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Re: shaping leading edge
« Reply #3 on: July 07, 2012, 08:51:29 PM »
  I sure don't want to "gouge" the l/e sheeting when shaping the leading edge, so all help/suggestions will be appreciated.

   Put a line of masking tape on the sheeting right behind the LE wood, root to tip, on both sides. Use a razor plane to carve away the majority of the excess wood, leaving the cut surface tangent to the sheeting Finish both top and bottom that way, and make sure that the "flat spot" at the LE is centered on the marked centerline. Then sand it with a long sanding block with maybe 180 grit all the way to the tape using light pressure. If you feel the tape start to ball up, stop, and replace it. Then start knocking off the corners with the plane again, keeping it centered. As you get close, change to moving chordwise, cross-grain, with a pull from the sheeting to the centerline, rounding everything off. When you think you are about finished, remove the tape, sand conventionally to smooth it all out.

     If you do get some gouges in the wood, wet them with straight water, and then hit it with a monokote iron.

        Brett

Offline Bill Little

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Re: shaping leading edge
« Reply #4 on: July 08, 2012, 01:40:34 PM »
Hi Gil,

I think Brett explained it a LOT better than I could have.  His technique is the same way I do it.

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Offline Allan Perret

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Re: shaping leading edge
« Reply #5 on: July 09, 2012, 06:36:07 AM »
What Dan and Brett said about the tape.  That's what I do.  But there is also another good tip to doing a better job.  Take the time to build yourself a jig to securely hold the wing in a vertical position, at a comfortable working height.  That will really inprove the quality of your work.  When I realized I needed something like that (about 6 wings ago) it only took about 2 hours to put something together from scrap materials I had laying around.  Even if you had to go buy the materials it would only be about 20 bucks.  Best investment of 2 hours time I ever made.  I can also put the wing in the jig facing down to work on the hingeline.  If you want to have perfect LE's and hinge alignment, start by building a jig.  Will dig up some pictures later.        
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Offline Bootlegger

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Re: shaping leading edge
« Reply #6 on: July 09, 2012, 08:54:43 AM »

        10-4 Jig Man, lookin forward to seein the jig pictures...
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Offline Brett Buck

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Re: shaping leading edge
« Reply #7 on: July 09, 2012, 10:18:06 AM »
What Dan and Brett said about the tape.  That's what I do.  But there is also another good tip to doing a better job.  Take the time to build yourself a jig to securely hold the wing in a vertical position, at a comfortable working height.  That will really inprove the quality of your work.  When I realized I needed something like that (about 6 wings ago) it only took about 2 hours to put something together from scrap materials I had laying around.  Even if you had to go buy the materials it would only be about 20 bucks.  Best investment of 2 hours time I ever made.  I can also put the wing in the jig facing down to work on the hingeline.  If you want to have perfect LE's and hinge alignment, start by building a jig.  Will dig up some pictures later.        
The JigMan

    Good idea.

    BTW, the cross-grain/chordwise part with a rigid sanding block is really important. If you sand entirely spanwise, the tendency is to sand more in the middle than the ends, and you end up with a LE that is curved in plan view, and blunter in the middle than the root and tip.

    Brett

Offline Avaiojet

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Re: shaping leading edge
« Reply #8 on: July 09, 2012, 11:47:39 AM »
What Dan and Brett said about the tape.  That's what I do.  But there is also another good tip to doing a better job.  Take the time to build yourself a jig to securely hold the wing in a vertical position, at a comfortable working height.  That will really inprove the quality of your work.  When I realized I needed something like that (about 6 wings ago) it only took about 2 hours to put something together from scrap materials I had laying around.  Even if you had to go buy the materials it would only be about 20 bucks.  Best investment of 2 hours time I ever made.  I can also put the wing in the jig facing down to work on the hingeline.  If you want to have perfect LE's and hinge alignment, start by building a jig.  Will dig up some pictures later.         The JigMan

Allen,

Gee Allen, I have plenty of projects going, in fact, I'll be making wings shortly for The Flamingo.

 I could certainly us a jig to speed up the process. I've thought about jigs but could never quite figure something out.  n~

The Flamingo has an upper and lower wing, a jig could be the ticket!

Sure, photos ASAP would be really appreciated.

I'm looking forward to them, so is The Flamingo.

Thanks,

Charles
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Offline Allan Perret

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Re: shaping leading edge
« Reply #9 on: July 09, 2012, 01:33:23 PM »
       10-4 Jig Man, lookin forward to seein the jig pictures...
Base is 3/4 plywood, like I said, scrap that was hanging around looking for something to do.  I have plenty of scrap.
Ripped a piece of 2 by 4 about 2" wide, thats the spacer at the bottom between the 2 "claws".
Claws are made from 1/8" pressboard,  stiff but flexible to conform to taper of wing.  
U shaped cutout in middle of claws has 2 purposes.  
1>Allows clearance for bellcrank post before its cut to final length.  (I dont cut the post till after it's in the fuse)
2>Divides the left and right sides of the claw so they can flex opposite to each other to match the tapers on both wing panels.
The two clamping screws are just long carrige bolts (1/4x20) with black plastic knobs (about $2 at the hdwe store)
Forget about the long strips of aluminum, I just used that in place of washers because it was laying around.

Put a couple pieces of soft rubber tubing over the carrige bolts between the claws to protect wing from getting damaged by the threads.  
Sometimes if just doing light sanding work on wing and dont need it to be held real tight, I will just put wing between claws and let it rest on the bolts.
Invest a couple hours in a wing holding jig and you'll be glad you did.  
Allan Perret
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Offline Bootlegger

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Re: shaping leading edge
« Reply #10 on: July 09, 2012, 01:52:19 PM »

  Allen, I like the way that you make something so simple, that look's real good, and as I sais so simple, even I can make one.

  Now for the other question, why is your shop so clean?  Makes me SICK!!!   LOL, LOL    n~
  Thanks a lot, GIL
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Offline Avaiojet

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Re: shaping leading edge
« Reply #11 on: July 09, 2012, 02:25:31 PM »
Allan,

All kidding aside. WOW!!

You do good work. Kudos!

BTW. The wing looks perfect! Looks like you also picked the balsa wood special for that wing. Does that wing belong to a kit?

Your Jig? I know what modelers will say, "Why didn't I think of that?"

Every time I thought jig, the design would be over designed and I would never get to it.

You nailed it!

I actually have the .75" base and the 2x4 which I can rip on my neighbors table saw, which is kindly taking up space in my garage.

If knobs aren't available, wing nuts would be fine, just have to be careful.

You know, a couple of dowel holes, at the top to support a base, and your jig could hold a fuselage.

You could also contact cement carpet foam to each side of your claws.

Well I asked for photos, and I'm more than delighted with them.

Thanks for that!

Charles
Trump Derangement Syndrome. TDS. 
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If you're Trolled, you know you're doing something right.  Alpha Mike Foxtrot. "No one has ever made a difference by being like everyone else."  Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten. "No amount of evidence will ever persuade an idiot."- Mark Twain. I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.   Proverb 11.9  "With his mouth the Godless destroys his neighbor..."  "Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

Offline Allan Perret

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Re: shaping leading edge
« Reply #12 on: July 09, 2012, 03:22:28 PM »
  Allen, I like the way that you make something so simple, that look's real good, and as I sais so simple, even I can make one.

  Now for the other question, why is your shop so clean?  Makes me SICK!!!   LOL, LOL    n~
  Thanks a lot, GIL
Keeping jig design simple is important, only then will you stop what you're doing and make it. 
But then the rewards come and you wonder why you didnt do it sooner.
Thats an old picture from when I was building the RMD (about this time 2010).
Shop aint so clean right now, lots of stuff going on, planes and otherwise..
Allan Perret
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Offline Dan Bregar

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Re: shaping leading edge
« Reply #13 on: July 09, 2012, 05:22:33 PM »
Allan you are very close to being a genius.   #^
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Offline Allan Perret

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Re: shaping leading edge
« Reply #14 on: July 09, 2012, 07:38:56 PM »
Allan you are very close to being a genius.   #^
Naw, this aint genius, just a little problem solving.  
Its simply recognizing a need and figuring out a solution.    
Anybody can do that if they use a little gray matter.
 :!
 
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Offline Dan Bregar

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Re: shaping leading edge
« Reply #15 on: July 09, 2012, 08:16:18 PM »
And your Humble too !!! ;D
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Offline Dick Pacini

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Re: shaping leading edge
« Reply #16 on: July 09, 2012, 09:25:13 PM »
Great looking jig.  What is the length of it? 
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Offline Allan Perret

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Re: shaping leading edge
« Reply #17 on: July 10, 2012, 09:04:24 AM »
Great looking jig.  What is the length of it?  
Base is 20" wide,   15" deep
Jaws are 20" wide,   12" high

When I use it for shaping / sanding LE, I clamp it in the jig offset to the panel I am working on.  I put the wing all the way down till trailing edge rest on the 2 clamp bolts and then tighen the jaws so its secure.  I will either clamp or screw jig to workbench, or sometimes put heavy weight on backside of base.  The wing is held tightly (with no damage) and I can do pretty much what I want and it does not move.  That makes it much easier to do your best possible job, and develop new skills along the way.

I have also clamped many times a balsa sheeted foam core wing with ZERO damage to the sheeting.  The Novar wing was in and out of this jig probably 20 times in the course of shaping LE, TE, and hinge installation.  

This one works fine, but if I was to make another one, I would increase width to 24"~26".
« Last Edit: June 26, 2013, 06:18:03 AM by Allan Perret »
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Offline Avaiojet

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Re: shaping leading edge
« Reply #18 on: July 10, 2012, 09:26:41 AM »
I've already started mine!

I'll have photos.

Thanks Allan!

Charles
Trump Derangement Syndrome. TDS. 
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Amazing how ignorance can get in the way of the learning process.
If you're Trolled, you know you're doing something right.  Alpha Mike Foxtrot. "No one has ever made a difference by being like everyone else."  Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten. "No amount of evidence will ever persuade an idiot."- Mark Twain. I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.   Proverb 11.9  "With his mouth the Godless destroys his neighbor..."  "Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.


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