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Apr 26, 2003, 12:55 PM
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Here we go. I figured it would be less confusing to start a new thread just for building.

Gregg introduced me to the razor saw which works very easy in cutting the hatch.

First I marked the hatch lines with a pencil.

Then taped over it and re marked the line again.

I started by cutting the top of the fuse, it's easier to start than the sides.

Once I cut both of those I started the sides with an exacto blade and then finished with the saw. It cuts like butter.

The saw is an extra fine exacto razor saw to be exact.

Didn't take long at all and the cuts are very straight.

Tomorrow I'll place the carbon spar, which keeps the the rigidity of the fuse while continuing to build.

Then I'll show you how the hatch will seal correctly.

As you can see the there's all kinds of room to place the ducting and fan. All I had around was a KY unit and even it fits with room to spare.

The fuse I'm using is was number two from the mold. The new ones are much cleaner inside. Still very usable.

More tomorrow.

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Apr 26, 2003, 12:56 PM
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cutting the top first.
Apr 26, 2003, 12:57 PM
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hatch cut open.
Apr 26, 2003, 12:58 PM
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Lots of room in there. Looks like a fast build so far.

More later.

Apr 26, 2003, 01:41 PM
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great pictures, Steve. where am i on your shipping list ?
Apr 26, 2003, 03:08 PM
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Is there a template to mark the hatch, or are the measurements somewhere?
Apr 26, 2003, 03:22 PM
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There's a line in the fuse that marks it.

It's hard to see but when you angle it to the light source it shows up. I just marked it with a pencil to see it better.

I may mark them with a fine pen before I send them out. Might help.

Apr 26, 2003, 03:31 PM
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Okie Doakie.
Apr 26, 2003, 05:13 PM
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I used a 1/4 inch carbon tube for the spar.

Drilled a hole 4 1/4 forward from the TE and 3/8 down from the top of the wing filet.

I made the hole a little under sized and used a reamer to get it just right.

Spar is 12 inches long, make sure you have in even and straight.

It's pretty easy.

I used a little CA to hold it in place until you epoxy and micro balloon it securely.

Apr 26, 2003, 05:17 PM
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Next I located another set of holes 3/4 back from the LE and 1/4 down.

You may have to do a little adjusting to get it pararell and fill in any gaps with epoxy and balloons.

This piece adds more strength to the fuse and gives you a nice tray to mount the battery to. Also a little more bite for the wings.
Apr 26, 2003, 05:19 PM
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Eventually we will add a ply tray, but this is the idea.
Apr 26, 2003, 05:20 PM
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Micro balloons and epoxy added.

Now to the hatch.

Apr 26, 2003, 06:41 PM
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Ok the hatch went pretty easy.

First thing is to cut some the fiber glass strips included to 1/4 inch wide. Also cut some 1/2 inch strips.

Glue the strips to the locations as shown, on the inside of the fuse.
Apr 26, 2003, 06:43 PM
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Glued to the inside of the fuse so a little more than half it's width is sticking up.
Apr 26, 2003, 06:45 PM
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Do this to both sides and the curves.

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