Join The Wing Panels; Build The Ailerons - GREAT PLANES Pete'n Poke Sport 40 Instruction Manual

Join the Wing Panels

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1. Test fit both wing panels to the center-section. Lay the
wing on your flat workbench and place weights on the
center-section to hold it down. Raise both wing tips 1/4" by
placing a leftover 1/4" balsa stick under rib W6 on both ends
of the wing. Make adjustments where necessary for a good
fit between both outer panels and the center-section.
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2. Once you have achieved a good fit between the joining
wing sections, mix up a batch of 30-minute (or 45-minute)
epoxy and coat all joining surfaces. Join the outer panels to
the center-section the same as you did in the previous step
(with weights on the center-section and both tips propped-
up 1/4"). Use clamps to hold the pieces together. Use
T-pins to hold ribs W2 and W2-A to W1 and W1-A. Wipe
away excess epoxy before it hardens and do not disturb the
wing. If there is a gap between the top outer panel spars
where they join the top center-section spars, add
microballoons or milled fiberglass to the leftover epoxy and
use it to fill the gap.
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3. After the epoxy has fully hardened, remove the wing
from your workbench and take off the clamps. Use a hobby
knife to trim any excess blobs of epoxy and sand the top and
bottom of the wing.
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4. Guide a piece of string through both wing panels from
rib W4 into the center-section. Later, the servo wires will be
attached to the string so they can be pulled through a hole
that will be cut in the bottom of the center-section for
connecting to the receiver.
Refer to this photo for the following four steps.
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5. Pin the right wing panel to the building board. Sheet
the top of the right wing panel using the remainder of the
3/32" x 4" x 30" balsa sheet you cut the shear webs from.
Note that the sheet must be shifted slightly forward of the top
main spar, so it will reach the sub LE (the gap between the
sheet and the top of the ribs will be filled after the sheeting
is done). If necessary, soften the outside of the sheet by
dampening it with window cleaner or water so it will bend
around the ribs easier.
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6. Remove the right wing panel from the building board.
Pin the left wing panel to the building board and sheet it the
same way.
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7. Fill the gap between the tops of the ribs and the LE
sheeting with leftover 1/8" balsa. Sand the sheeting even
with the sub LE and the wing tip. Sand the spars even with
the wing tip.
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8. Glue the 3/8" x 7/8" balsa leading edges to the wing.
Trim the LE's even with the sheeting and the wing tip, then
final-shape them as shown in the cross-sections on the plan.

Build the Ailerons

The ailerons are built on the plan with the wing in position,
thus ensuring the best fit.
Refer to this photo for the following four steps.
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1. Place the right wing panel plan over your building
board and cover the aileron plan with Great Planes Plan
Protector. Align the right wing panel with the plan and pin it
into position.
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2. Mark the location of the aileron ribs on the top of
the die-cut 1/8" balsa aileron base.
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3. Cut the aileron leading edge to the length shown
on the plan from the remainder of the 1/4" x 3/4" x 30" balsa
stick you used for the outer TE of the wing. Use T-pins or
clamps to hold the aileron LE to the outer TE.
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