Install Wing Fillets - GREAT PLANES Ultra-Sport 1000 Instruction Manual

with new #50 or #80-grit sandpaper for rough shaping
The very coarse sandpaper is used to achieve the
basic shapes Then use progressively finer grades of
sandpaper for a smooth finish.
D 1 Turn the fuse upside down You have already
shaped the aft end of the chin block, and you don't
want to change that shape, so apply a strip of
protective masking tape to the chin block near the aft
end Now study the fuse plan side view and note the
final shape and curvature of the chin block Use your
razor plane and a sanding block with coarse
sandpaper to sand the fuse bottom to the approximate
shape as shown on the plan
D 2 With the fuse right side up, draw a line across
the aft end of the top front block, approximately 1/16"
down from the top edge Now study the fuse plan side
view and note the final shape and curvature of the top
front block Then sand the top front block to the
approximate shape shown on the fuse plan side view.
D 3 Now sand the chin block, the top front block
corners and the cowl side pieces to blend smoothly
with the spinner ring
drawings of F-1 and F-2 on the plan to get an idea of
the desired amount of rounding in the corners
top front block should be sanded with reference to the
instrument panel (see the photo below)
edge should end up approximately 1/4" from the edge
of the instrument panel, following the same curvature
around the corners For additional guidance, you may
cut out one side of the F-1 drawing, glue it to a piece
of wood and cut it out around the perimeter to make a
checking template, then cut the template in half, so
you will have separate templates to check the top and
bottom curvature in the F-1 area
these templates "TOP" and "BOTTOM "
Refer to the cross-section
The
the top
Be sure to mark
D 4 After the rough sanding has been completed,
temporarily re-mount your engine and slide on the
spinner backplate You'll probably have to sand down
the edges of the spinner ring for a good match with the
spinner backplate.
D 5 If you have not already done so, sand the
bottom rear corners of the fuselage to a slight radius
as shown on the cross-sections of F-5 and F-6, but
don't change the fuse bottom shape at the wing TE.
D 6. Now, with the engine and mount removed,
fuelproof the inside of the entire engine compartment
with polyester resin or epoxy thinned with alcohol
INSTALL WING FILLETS (OPTIONAL)
PARTS NEEDED-
D (1) US10F36
Filler or scrap soft balsa (see below)
NOTE: The wing fillets are a nice addition to the
US1000 They make it more pleasing to the eye
and they do help to reduce drag The US1000 flies
just fine without them, however, so the choice is
yours whether or not to install them.
D 1. Tape a 10" x 19" piece of waxed paper or plastic
wrap onto the top surface of the wing at the center,
wrapping it around the LE and TE, then attach the
wing to the fuse with the wing bolts
D 2 Lay the die-cut 1/32" ply wing fillet bases on the
wing and glue them to the fuselage sides NOTE: For
this procedure, we recommend that you use thick CA
glue sparingly, and "kick" the glue with accelerator
spray immediately after applying, to avoid accidentally
gluing the wing to the fuse with "stray" glue NOTE:
Bend the aft 1-3/4" of the fillet base to horizontal (see
sketch)
Wing
43
Die-cut 1/32" ply Wing Fillet Bases