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ERacer Aircraft Construction Website

Our Goal: To safely build and fly the ERacer
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ER CONSTRUCTION LOG
Chap 1-4 Fuselage
Chap 5 Nose Structure
Chap 6 Main Spar Construc
Chap 7-8 Cabin and Contro
Chap 9 & 13 Canopy/TDeck
Chap 10 Landing gear Syst
Chap 11 Wings and Winglet
Chap 12 Strakes and Fuel
Chap 15-16 Canard Constru
Chap 17-18 Engine Install
Chap 19 Cowling Construct
Chap 20A Surface Finish
Chap 20B Painting
Chap 21 Panel and Electri
Chap 22 FAA Inspection
Chap 23 Flight Testing
ERacer Landing Gear Kit
Eureka Wing Cores
ERacer Merchandise
Canard Covers by Doroth
ER Builders/Flyers List
Shirl Dickey's ERacer
Tom Koftinoff's ERacer
Erik Frank's ERacer
Cliff Cady's ERacer
Bruce Vinnola's ERacer
Rob Orsolits' ERacer
Tore Bjoelgerud's ERacer
Mitch Hargin's ERacer
Mark Fisher's ERacer
Andre Rousseau's ERacer
Tommie Turner's ERacer
Kim Riley's ERacer
Daniel Muller's ERacer
David Hanson's Canard X
Joel Aubry's ERacer
Jack Morrisons ERacer
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Chapter 11   Wings and Winglets
 
 
MAIN WINGS:
 
Left: Foam block measured, marked,  ready for initial hot wire cutting.
Right: These are the wing Jigs bondo'd to the floor...ready for foam cores.
 
 
Left: This was the 4' hot wire cutter..we also used a home-made 6' cutter for the large pieces.
Right:  Piece of the trailing edge foam core complete. 
 
Left: Here is a shot of the above piece prior to cutting.  Note the wing template attached to the foam material. 
Right: Pic of the interior aileron template prior to cutting of the aileron torque tube hole.  That square cut-out section is later glued back in after the interior of the  future aileron is cut out. 
 
Left: Checking the cores prior to placing in the wing jig.
Right: Trailing edge foam cores mounted into the wig jig waiting for cap spar lay-up. 
 
 
Left:  Using a dremel with router blade to dig out areas for the hard points.
Right:  This shows the lay-ups on the wing bolt access channels. 
 
Left: Bolt access channels complete with hard points and sheet alum. covers.  Ready for spar cap layup. 
Right: Pic shows the initial layers of the spar cap glass lay-up into position.
 
Left:  Spar cap complete and peel ply covering.
Right: Leading edge foam cores micro'd into position on top of the spar cap.
 
Left:  All wing foam in the jig and curing.
Right:  The jig is then taken off the floor and layed onto the work table for next layups.
 
 
Above:  The bottom halves of the jig are bondo'd to the work tabe and the othe halves are removed for the next wing spar layups.
 
 
 
Left:  Unidirectional glass is layed into the channel for the upper and lower wing spar layups.
Right:  Then the wing in covered in bi-directional glass lay-ups.
 
Left:  Pic of one wing completely glassed on both sides awaiting the final aileron cutting.
Right:  Cutting out the aileron with a dremel and my home-made angle cutting tool. 
 
Left:  Shows the installation of the aileron hinges.
Right:  One aileron cut out complete.
 
 
Left:  Both wings complete (except for winglets) awaiting the final aileron installation.
Right: Aileron installed on one wing.
 
Left:  Aircraft leveled and both wings in position for initial mounting procedures.
Right:  This is a pic showing how the ERacer push-pull aileron control cables hook into the aileron bell crank and control the ailerons on this aircraft.
 
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 WINGLETS:
 
 
Left:  Winglet template attached to foam prior to hotwire. 
Right:  First winglet foam core cut out and pieces glued together.
 
Left:  Glass lay-ups on one side of the winglet.
Right:  This is a completed winglet with the bottom edge cut for attachment and rudder line marked prior to cutting.
 
Left:  Winglet bondo'd into correct position with a wood temporary support.
Right:  Winglet attach point...ready to begin series of attachment layups.
 
Left:  First attachment lay-ups on interior edges.
Right:  Next layers of glass laid and peel-ply'd.
 
Left:  Pic of interior lay-ups after cure...ready for next steps.
Right:  Positioning the foam for next surface addition.
 
Left:  Foam is micro'd in and shaped.
Right:  Pic shows outer structural lay-ups attaching the winglet to the wing.
 
Left:  Now more foam is micro'd into position for further shaping.
Right:  Foam is carved into final wing shape.
 
Above:  Final lay-ups are made to the outside of the winglet.
 
 
Left:  Pic shows the rudder hinges, rivets, screws, hooks and return springs needed for rudder completion.
Right:  Rudders are cut out and aluminum rudder horns are installed at the base of each.
 
 
Left:  Shows the inboard structural lay-ups needed for winglet attachment to the wing.
Right:  Rudder installed on winglet.