Fit Wings - Pro Built GILES 202 Assembly Instructions Manual

aking pushrods that will withstand the forces involved in a large plane of this type is very
simple once you see how it is done. If you have your own design, feel free to use it, but
here's one that is cheap and strong.
You will need a length of 3/16" carbon fiber or fiberglass tubing, a length of 4-40 all-
thread rod, and some 4-40 nuts.
First, set up your linkage using the clevises and the 4-40 all thread cut to the proper length.
You can make all your pushrods at once, so get all those rods set to the right length. If you
use a metal clevis, be sure the pushrod goes all the way into the threaded section, plus a little
to allow a range of adjustment. With plastic clevises like Dubro , the rod should screw into
the clevis about 1/2 inch to be sure there is sufficient strength.
Measure each pushrod, and cut a piece of carbon-fiber tube that is 1 1/2" shorter than the
rod. Slip the tube over the rod and tighten down a nut from each end so that you leave an
equal amount of thread at each end to mount the clevis. Tighten the nuts slightly so they
don't come loose and so there is a little tension on the rod inside the tube.
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Fit wings

Push the 1.5 inch aluminum tube spar through the tube in the fuselage until it protrudes an
equal distance on both sides.
Carefully push each wing onto the tube until the anti-rotation dowels engage the holes in the
fuselage side. As the wing approaches the fuselage guide the aileron extension through the
access hole.
The wings mount to the fuselage with two 4mm socket head screw on each wing through
the fuselage side. You can also drill the ant rotation dowels to accept hairpins for safety
(see photo).
Use no larger than a 1/16" drill and pin to avoid weakening the dowel. Do not rely on the
dowels alone, they are not meant to be used as permanent retainers but will work in an
emergency.
Use a large washer on the 4mm screw to keep it from pulling through the hole in the fuse
side, or install a small aircraft ply "cookie" as shown to reinforce this area.
The holes are intentionally made slightly oversize to allow for alignment variances, but
once your cookie is properly positioned you can glue it in place with thin CA to make a
permanent and accurate installation.
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