Wing Assembly; Assemble The Wing Joiners; Join The Wing Panels - GREAT PLANES Easy Sport 40 Instruction Manual

WING ASSEMBLY

Assemble the Wing Joiners

Note: As epoxy is used for most of this kit's assembly, it's a
good idea to keep rubbing alcohol and paper towels handy
for cleanup. Before the epoxy has had time to cure, moisten
a paper towel with alcohol and clean off any excess epoxy.
❏
1. Lightly sand the edges of the three plywood wing
joiners to remove any rough edges. Use 6-minute epoxy to
glue the three pieces together. Be sure that the slight
dihedral angle is on the same edge of all three pieces.
Clamp the wing joiners together or weigh them down on a
flat surface while the epoxy cures.

Join the Wing Panels

❏
1. Draw a centerline on the wing joiner as shown in the
photo. Test fit the wing joiner into each wing panel. You
must be certain that the joiner fits all the way into the wing
panels. The joiner should fit snugly into each wing panel.
Sand the joiner if it does not fit snugly or does not fit
completely into the wing panels.
❏
2. Sand the inside of both wing roots for a nice flush fit.
Test fit the panels together with the wing joiner in place.
The angled edge of the joiner points towards the bottom of
the wing. Check the alignment of the leading and trailing
edges. They should line up nicely with the roots fitting
together without any gaps. Sand the root ribs if any
imperfections are keeping the wing halves from fitting
together properly.
Carefully read and practice the following step
completely before mixing any epoxy. The entire step
must be completed before the epoxy begins to set.
❏
3. When you are satisfied with the fit, pull the panels apart
and mix up a large batch (about 3/4 oz.) of 30-minute
epoxy. Using an epoxy mixing stick, liberally spread epoxy
inside both of the joiner slots and on one half of the joiner
itself. Next, quickly install the glued end of the joiner into one
of the slots. Spread more epoxy onto the root ribs and the
protruding end of the wing joiner. Slide the two wing panels
together. The epoxy should squeeze out around the edges.
This is a good sign that there is enough epoxy to securely
join the two wing halves. Double check the alignment and
wipe off any excess glue with a paper towel and rubbing
alcohol. Hold the two wing halves together using masking
tape. Continually check the alignment of the wing halves
while the epoxy cures.
❏
4. Once the glue has cured, check the joint for any small
gaps and fill them with epoxy. Wipe off any excess epoxy
using a paper towel and rubbing alcohol. The paper towel
can also be used to remove any fingerprints or epoxy
residue that may have been left behind.
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