Perhaps one of the biggest hurdles involved in building a Sport Goodyear is carving the wing. Recently, I have found a way to clear this hurdle with a minimum of effort. It only applies to constant chord wings, such as found on the Buster, Bonzo, Zipper, Stardust, and a whole plethora of Cassutts.
The good folks at Brodak sell a replacement wing for their Flight Streak Trainer for $16.00. (It is listed in the paper catalog, but I could not find it online). The wing is one piece, 6" chord, about 37" span, and a bit over 3/8" thick. It has a pre-carved flat bottom airfoil, with a 1/8" thick trailing edge to accomodate the Streak Trainer's fixed flaps. It is the top wing in the photo.
I personally wanted a wing with 6 5/8" chord for my new BooRay. First, I cut the wing apart 2" from the leading edge, and added a 1/4" x 3/8" spruce spar. This increased the chord by 1/4". Then I added a 1/8" x 3/8" spruce trailing edge, which increased the chord to the desired 6 5/8". I also cut 1/4" off the leading edge, and replaced it with 1/4" x 1/4" spruce for strength and impact resistance. This is the middle wing in the photo.
Once this was done, the spruce leading and trailing edges were shaped, and the high point of the wing sanded to blend everything together. The bottom wing shows the finished airfoil.
If a narrower chord is needed, a section of balsa may be removed from the high point area of the wing. For example, cut the wing leading edge at 1 3/4", then cut 5/8" off the front edge of the back part of the wing. Add the 1/4" spar and 3/'8" trailing edge, and you are back to a 6" chord. This would be appropriate on the Stardust, for example.
It will also be necessary to install some sort of hard point for mounting the bellcrank. I recommend the tapered maple spar/ bellcrank mount as featured on the Margaret June plans. This may be installed after the wing is assembled, but will be easier to fit and install before gluing the wing together.
Hopefully, this will be just what some of you need to start building your own Sportsman Goodyear racer.