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

wing cradle where former 5 and the crutch meet.
Draw a 6" line on the fuse as shown. This will be a
guide to position the aft portion of the ply wing fillet
base later.
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6. Use masking tape to hold the die-cut 1/32"
plywood wing fillet bases to the fuse crutches.
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7. Place the wing on the fuse. As best as you can,
center the wing dowels in the oversized holes in F2.
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8. Stick a T-pin into the center of the bottom of the
aft end of the fuse. Align the wing using the same "pin
and string" technique we showed you for aligning the
stab. Once the wing is aligned, place weights on the
bottom of the wing to hold it in position while you drill
the wing bolt holes in the next step.
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9. Using the 1/4" holes in the sheeting and the wing
bolt plate inside the wing as a guide, drill #7 (or
13/64") holes through the wing bolt blocks in the fuse.
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10. Remove the wing from the fuse. Enlarge the
holes in the wing bolt plate in the wing with a 17/64"
drill. Enlarge the holes in the bottom sheeting to
accommodate the head of the nylon 1/4-20 wing
bolts and the paper wing bolt tube (refer to the
photo at step 11 of Build the Belly Pan).
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11. Use a 1/4-20 tap to cut threads in the wing bolt
blocks in the fuse. Add a few drops of thin CA to the
holes and allow it to harden. Retap the holes.
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12. Reposition the wing on the fuse and bolt it in
place with the fillet bases still taped down.
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13. Stand approximately ten feet behind the model
and view the alignment of the stab and wing. If
necessary, place shims made from leftover balsa
between the fillet and the fuse to bring the wing into
alignment with the stab.
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14. Once you have achieved alignment, use
30-minute epoxy to glue the laser-cut plywood wing
dowel doublers to former 2. Be certain you have not
glued the dowels to the doublers. Do not disturb the
model until the epoxy has fully cured.
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Build the wing fillets

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1. Turn the model right side up and place it on its
landing gear or in your building cradle. Check to make
sure the ply fillet bases are positioned correctly and
that they will fit the wing. Make adjustments where
necessary. This may require removing the wing and
repositioning the fillets a few times.
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2. Place the model upside-down in your building
cradle and remove the wing and ply fillet bases.
Protect the center section of the wing with wax paper
or Great Planes Plan Protector so glue from the wing
fillet bases will not adhere.
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3. Glue the wing fillet bases to the fuse with a
mixture of 30-minute epoxy and microballoons or
other suitable filler. Working quickly before the epoxy
cures, tape the fillet bases back into position and bolt
the wing to the fuse. Reposition the model on your
workbench right side up and wipe away excess
epoxy and filler. Use whatever practical means
necessary to be certain the fillet bases are fully
contacting the wing (you can see in the photo that we
tack glued leftover balsa to the fuse, holding the fillet
down in the flap area). Do not disturb the model until
the epoxy has fully cured.