Build The Wing Panels - Top Flite P-47D Thunderbolt User Manual

Build the wing panels

We'll start with the right wing panel first.
Refer to this photo for the following six steps.
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1. Use large T-pins to securely hold one of the
main spars to your building board over its location on
the plan. The root end of the spar should extend
beyond the wing centerline approximately 1/16". Do
not use any T-pins outward of rib 10 as the spar is
going to be raised.
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2. Fit, but do not glue, the die-cut 1/8" balsa
inner TE spar into ribs 3 through 6, then join the
assembly to the bottom main spar on the plan.
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3. Join ribs 7 through 12 to the assembly, then
join the die-cut 1/8" balsa outer TE spar to ribs 8
through 12.
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4. Use some of the 1/4" x 1/4" rib jigs leftover
from building the tail surfaces to hold ribs 2A, 2B,
2.5, 3 and 3.5 over their position on the plan. Use rib
jigs on other ribs as necessary to help hold the wing
panel firmly to your building board.
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5. Place a shim made from leftover 1/8" balsa
under the bottom spar at rib 12. Rib 12 should have
rib jigs to hold it down.
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6. Be certain the jig tabs of all the ribs are
contacting the building board, then glue ribs 3.5 through
12 to the bottom main spar using a small builder's
square to hold the ribs vertical as you proceed.
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7. Fit, but do not glue the top spar and the
die-cut 1/8" plywood forward and aft spar joiner
braces to the panel. Make sure you have installed the
braces right side up (the root ends are cut at an angle
for dihedral). Be certain the top spar extends past the
joiner braces by 1/16", then glue the top spar to ribs 4
through 12, but not to the joiner braces.
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8. Making certain the jig tabs of the ribs are
contacting the building board as you proceed, glue
the outer TE spar to ribs 8 through 12 and glue the
inner TE spar to ribs 3 through 7.
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9. Cut a shaped 36" balsa leading edge to the
length shown on the plan. Glue the LE, centered
height-wise, to ribs 2A through 12 except for rib 2.5.
Note that the bottom of the LE near the tip will have to
be trimmed where it interferes with the building surface.
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10. Temporarily remove the aft spar joiner brace
and rib 2.5 from the assembly (the absence of rib 2.5
will allow positioning of a C-clamp on the bottom
spar and the spar joiner). Use 30-minute epoxy to
glue the forward spar joiner brace to the front of the
top and bottom main spars. Wipe away excess epoxy
before it hardens—especially from inside the spar
joiner to accommodate the wing joiner later on.
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11. Glue ribs 2A and 2.5 to the forward spar
joiner brace.
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12. Use 30-minute epoxy to glue the aft spar
joiner brace to the spars. Immediately after you
position your clamps, use a leftover piece of 1/4" x
3/8" basswood to scrape away excess epoxy from
inside the spars. Any epoxy left inside the cavity
made by the spars and spar braces will make it
difficult when inserting the spar joiner later on.