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Old May 27, 2008, 09:06 AM
Be afraid!
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Milano
Joined Dec 2003
458 Posts
Mini-HowTo
A wing fillet for Apogee

No maiden flighy yet for my Apogee, miserable weather again. So yesterday evening i've done that wing fillet you can find on almost all Drela projects: he says that, once installed, the plane is noticeably quieter on fast fly-bys, sure a good thing

On my first Apogee that fillet didn't come out as hoped: it was small, rough and rather brittle and was a lot of work too.
After some head scratching i've devised a simple and effective method.
You need some thin foam (1mm) some scrap 36g/mq kevlar, laminating resin and your filler/thickener of choice (i used some chopped fiberglass).

First you need to print the template, (squares are 4mm)cut it and tack on the thin foam. Then you need to cut the foam with a sharp cutter.
You now have this little half-moon of foam, but before to fit and wrap it on the intersection point you need to put some scotch tape on the wing.
You start with two stripes just outside the front locating pins and then some tape between(top and bottom). Take care not to have any wrinkles.
Rub the taped surface with some vaseline and screw the wing to the pod.
Now you can wrap the foam half-moon by tacking with some foam-safe cyano the inner central part to the pod and wrapping the two points under the wing, wedging the very points between the pod and the wing.
You take the kevlar, lightly mist with repositionable spray glue and put on a piece of baking paper.
With some sharp scissors you then cut the kevlar half-moon slightly oversize
(red line as reference), and respray a little and put on the foam half moon.
You then again wedge the points and tack with FS cyano.
Then you make a first small batch to saturate the kevlar, let harden a little and mix a second batch with your filler to the consistency of silicone using this to add some meat to shape.
Once cured you detach the wing,sand to shape using an half circle file and dissolve the foam with a small brush and nitro.
Lots of words but little work actually
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Last edited by Cuddles; May 28, 2008 at 11:11 AM.
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