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20050105 - allegro - 01 - capstrips
20050105-allegro-01-capstrips: The wrapped spar with cap-strips in place. Epoxy on the bottom capstrip and epoxy & microballoons on the top capstrip. The bottom cap-strip is almost entirely sanded...
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20050103 - allegro - 05 - wrappedjoinerbay
20050103-allegro-05-wrappedjoinerbay: The joiner bays are double (or triple) wrapped. I only did mine double. I'm trying to build light here, and don't plan on doing full-pedal launches, and in any...
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20050103 - allegro - 04 - wrappedspar
20050103-allegro-04-wrappedspar: Here I'm wrapping my mid-panel spars with 1/8" wide Kevlar thread. If the thread is flattening out into 1/8" wide ribbon, then the gap between wraps is a little less...
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20050103 - allegro - 03 - wettedglass
20050103-allegro-03-wettedglass: Wet the glass with some thin epoxy. I did not wait for this to lay up before I wrapped the spar with Kevlar. 20050103-allegro-03-wettedglass: Wet the glass with some...
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20050103 - allegro - 02 - adheredglass
20050103-allegro-02-adheredglass: Adhere the glass to the joiner box with some 3M-77, and wrap it around the joiner box. This may not be necessary, but I overlapped the glass on one side of the spar...
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20050103 - allegro - 01 - glassjoiner
20050103-allegro-01-glassjoiner: (Sorry for the long pause! I had to order more kevlar from CST, and then built my rudder and elevator, and then the holidays...) The next step is to start to wrap the...
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20041128 - allegro - 11 - midpanelsbeforewrap
20041128-allegro-11-midpanelsbeforewrap: After cleaning and radiusing, the tip and mid assemblies came in at 76grams. 20041128-allegro-11-midpanelsbeforewrap: After cleaning and radiusing, the tip and...
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20041128 - allegro - 10 - midpanelcleaned
20041128-allegro-10-midpanelcleaned: After a full day's cure, I removed the mid panels from the layup, trimmed/sanded away extra epoxy (there was not much) and sanded the carbon caps into a nice...
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20041128 - allegro - 01 - midpanellaydown
20041128-allegro-01-midpanellaydown: Mid-panel weighted down. On top of each spar I used a 1/4" strip of EPP and ensured that the tip carry-through segments were well weighted, as well as the joiner...
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20041127 - allegro - 08 - hardwoodsplooged
20041127-allegro-08-hardwoodsplooged: The basswood insert "splooged" into place. Note the extra epoxy here. This is a crucial joint. 20041127-allegro-08-hardwoodsplooged: The basswood insert...
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20041127 - allegro - 07 - vaselineepoxy
20041127-allegro-07-vaselineepoxy: The colloidal silica (Cabosil) thickened epoxy. "Vaseline" thickness as per Drela. It should stick to the side of the cup and not appear "fluid". Note that I use...
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20041127 - allegro - 06 - hardwooddryfit
20041127-allegro-06-hardwooddryfit: I did a little more fine sanding on the basswood insert. Also note that I had to sand the web for the carry-through strips. Be more accurate than I was here. I...
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20041127 - allegro - 05 - dryfit
20041127-allegro-05-dryfit: Mid panel pieces dry-fitted to (near) perfection. You made need to sand the ribs to fit the CF top-spar. Just a little, tiny bit, but it may be necessary. Note that I made...
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20041127 - allegro - 04 - hardwoodsandingjig
20041127-allegro-04-hardwoodsandingjig: To ensure flat tops and bottoms and a good 6 degree face, I made a small sanding jig on my work-surface. This was just a piece of hardwood CA'd to the glass....
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20041127 - allegro - 03 - trimmingglass
20041127-allegro-03-trimmingglass: To ensure a good and proper fit, make sure to trim/sand away any glass or epoxy that may hinder the bond. 20041127-allegro-03-trimmingglass: To ensure a good and...
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20041127 - allegro - 02 - joineruncutandcut
20041127-allegro-02-joineruncutandcut: After I got the basswood sanded "just so", I used a razor-saw and cut the width of the 1/2" wide pieces down to the 3/8" width needed for the spar. The leftmost...
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20041127 - allegro - 01 - hardwoodfit
20041127-allegro-01-hardwoodfit: You'll need to do a bit of sanding and fitting to ensure a good fit for the basswood pieces. 20041127-allegro-01-hardwoodfit: You'll need to do a bit of sanding and...
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20041126 - allegro - 02 - hardwoodgangup
20041126-allegro-02-hardwoodgangup: Using medium CA, I ganged the two basswood pieces together. 20041126-allegro-02-hardwoodgangup: Using medium CA, I ganged the two basswood pieces together.
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20041126 - allegro - 01 - hardwoodends
20041126-allegro-01-hardwoodends: While the joiner bars were being laid up, I started to make the basswood break inserts for the tip/mid break. These are made from the same 1/4" basswood stick as the...
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20041125 - allegro - 03 - joinerbarsweighdown
20041125-allegro-03-joinerbarsweighdown: Weighing down my joiner bars lay-up. 20041125-allegro-03-joinerbarsweighdown: Weighing down my joiner bars lay-up.
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