Originally Posted by R2R

Kurt,

Was it one plunge, or did you need to reheat the wire multiple times to make it all the way to the aileron servo?

As I recall it took several attempts. You don't need a very large piece of piano wire.

Thanks Kurt.

I used a piece of about 3/32" or 1/8" heated piano wire as I recall. IRRC it took one or two dips into the foam. I also had the wing laying on the bench and ran the wire along the inside of the skin where I wanted the hole. Didn't take much heat.

Ok. Thanks Mark.

Picked up a new router bit from the local hardware store. This time I did the hole in two passes, the first at half-depth. This along with the fresh, sharp bit seemed to prevent the foam from tearing out of the bottom.

AAAH, much cleaner cut, even through the balsa!

Originally Posted by Soarmark

AAAH, much cleaner cut, even through the balsa!

Today, I installed the towhook mount. I also double checked the wing joiner hole by creating a template traced from the actual wingroot. The pilot I drilled was right on the money.

I also tried to drill a wire tunnel using a sharpened 3/8" brass tube. I got half way to the aileron servo pocket and gouged the balsa from the inside and penetrated the skin. It is fixable with some lightweight spackle. However, i'm going to move on to using a hot wire to create the tunnel.

Originally Posted by R2R

I also tried to drill a wire tunnel using a sharpened 3/8" brass tube. I got half way to the aileron servo pocket and gouged the balsa from the inside and penetrated the skin. It is fixable with some lightweight spackle. However, i'm going to move on to using a hot wire to create the tunnel.

Actually the hot wire is much easier than you might think, it doesn't need to be cherry red. Also, another way to create a root template is to drill a hole for your joiner in a piece of plywood or some other sheet of material that is larger than the wing root. Put the joiner in the wing and the sheet of material over it at the root. Then trace around the the wing root, remove and cut out your template. I used that method to make shims to fill alignment gaps on a Spectrum 2 meter that has Fred Sage wings.

Mark

Originally Posted by Soarmark

Actually the hot wire is much easier than you might think, it doesn't need to be cherry red. Also, another way to create a root template is to drill a hole for your joiner in a piece of plywood or some other sheet of material that is larger than the wing root. Put the joiner in the wing and the sheet of material over it at the root. Then trace around the the wing root, remove and cut out your template. I used that method to make shims to fill alignment gaps on a Spectrum 2 meter that has Fred Sage wings.

Mark

Nice, Mark. This is why I love RCGroups.

Success! The hot wire worked, and the tunnel now extends to the aileron servo nook.

Today, the tunnel for the other wing came out well too. Moving on...

I finished my F3-RES build, so now I can come back to this.

Good thing about this build log is that I was able to use it to see where I left off.

R2R, any more progress?
I have an old 880 awaiting refurb and do appreciate any advice.

I finally got a little bit done on the Falcon -- just some razor planing of the LE basswood to take away excess wood and rough in the shape before hitting with sandpaper.

Originally Posted by Weav

Hey... R2R.... I don't know your name....

I made the Stab Bellcranks for Flite Lite Composites and Airtronics ... I also made the Composite Flap and Aileron horns...
Will be glad to ship them to you at No Charge.... The bell crank alone was a huge improvement. And it will fit your Stab tubes even though you already bonded them into place. I sent you a PM with some info......
Enjoy your build.... The Falcon 880 was a HUGE leap in Soaring technology back when Mark Allen first drew it up and made it. I remember flying one that belonged to a very young Bob McGowan at a high school in the Fremont area of Calif.... It flew so good..... and I mean SO GOOD... There is a reason many people built them and ultimately the Thermal Eagle... Those two airplanes really made huge inroads to higher performance Soaring during the late 1980's. The Thermal Eagle used the RG15 airfoils and really made for a slippery sailplane.
Anyway, I'm just trying to help you out. Send me some info so I can send you some parts.
Thanks,
Fred Weaver
Flite Lite Composites

Hi Fred.
I have a Flite Lite Composites Thermal Eagle that I want to start flying. I finished it many years ago, but never flew it. I just started flying again after a 20 year layoff. I have all of the parts to the TE, except the stab. Do you have any spares, or plans for building one? Thanks a bunch. Steve